United States
                   Environmental Protection
                   Agency
                Air and Radiation
                (6202J)
EPA-430-F-98-055
Fall 1998
                   AgSTAR  Digest
Inside...
AgSTAR: The Momentum Builds....1
Support Corner: AgSTAR Handbook
    &FarmWare	3
Environmental Corner: Manure
    Odors Raising a Stink	3
Showcase Corner
    Craven Dairy	4
    Martin Farm	5
Other Regional Activities Corner	6

New Participants	7
                                         Odors go up in smoke. Installation Crew at first gas flare lighting, North Carolina.
    AgSTAR has helped 6 Partner
   Farms establish farm profit and
   environmental centers with the
         implementation ofbiogas
                       technology.
AgSTAR - The Momentum Builds
    Over the past 18 months, six AgSTAR Partners have installed biogas  recovery
    systems and established new profit and environmental centers. This increase in
demand is the  largest experienced since the mid-seventies.  At least 10 more biogas
projects are in either planning or  construction  phases.   See  the Showcase and
Regional Corner for some specific farm details.  By all indications 1999 will see even
larger demand  based on  AgSTAR  program  participation, hotline activity, feasibility
assessments, and project planning requests. The  difference is  that today commercial
systems are more reliable  due to improved design, equipment, technical support, and
on-farm innovation.   The best innovation we have seen is a complete retro-fit of 2
farrowing houses with heat mats at a 4,000-sow Partner farm.  Biogas is used to heat
water in a boiler, which is circulated through the farrowing buildings.

These days, producers are selecting biogas technologies for multiple benefits, not
solely for energy production. Highest on the environmental benefit list is odor control.
All properly designed biogas systems substantially reduce odor. Several dedicated,
heated odor control digesters have been built in the last year. Basically an odor
control system collects biogas to fuel a boiler that in turn heats the digester. Heating a
digester decreases the volume needed to stabilize manure by speeding up the
biological (anaerobic) process that destroys odor-producing compounds in the manure.
Controlled high  temperature decomposition in a digester will also reduce pathogens, a
major concern in water quality circles today. Dairy farms using scrape manure
collecfon benefit the most from  heated digesters because the digested dairy manure
yields a high grade, weed and  pathogen-free fiber that has commercial value in the
potting soil industry;digested dairy manure can be sold for $4-8/cubic yard.
                                                                                  (continued on page 2)

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   AgSTAR-The  Momentum Builds  (continued)
   Other AgSTAR Program highlights include:
    ĞT  Publication  of  National   Interim   Standards  for  Biogas
        Systems  by   USDA's   Natural   Resource  Conservation
        Service (NRCS).  The  United States  is now one  of a few
        countries  to  have  such  standards.    Interim   Practice
        Standards on  Covered  Lagoons,  Plug Flow  and Complete
        Mix Digesters can be found through the World Wide Web at
        the following address: http:/www.ftw.nrcs.usda.gov.

    >*  An  improved  Memorandum  of Understanding  (MOU) for
        Partners and Allies.  The  revised MOU is a simple one-page
        voluntary  agreement.  In  addition  to emphasizing  methane
        recovery,  the  revised  MOU recognizes the rnportance of
        odor control and containment as  a common environmental
        AgSTAR  goal  because  of  increasing   odor  concerns
        surrounding confined  livestock  facilities.     Manure  odor
        management is discussed in  the  Environmental Comer on
        page 3.

    >*  The Environmental  Recognition component of the  program.
        Operating Partner  Farms  are  awarded with  a  25" x 12"
        weather  resistant,  "EPA  Partner  Farm" sign that can  be
        displayed  at  farm  entrances  or  along  side  other  farm
        insignia as at  Craven Dairy (shown below).  The  AgSTAR
     AgSTAR Partner, John Craven Jr., under his Partner Farm Sign

        Program  is   also  in  the   process  of  developing  an
        Environmental   Steward   certificate   (illustrated   in   the
        Showcase Comer,  page 7).   This  81/2 x 11  certificate is
        suitable for framing and office display.  As  future  Partner
        farms   go  on-line,  these  symbols  of   environmental
        recognition will be awarded bgether.

     V  The release of the AgSTAR Handbook including FarmWare
        version 2.0.   These tools are provided  to  assist in the
        project  development process based  on technology choice,
        operational    ability,     financial     performance,    and
        environmental  performance.   See the Support Corner tor
        details.
w  Educational  and training workshops.   The  most  recent
    workshop  was held at  the McKimmon Center in  Raleigh,
    North  Carolina.    Over  100  individuals  -  representing
    producers,  the  agricultural industry,  and state  agricultural
    agencies  attended  this  workshop  entitled   "Methane
    Recovery as a Cost Effective  Environmental Opportunity for
    Livestock  Producers."   This  two-day event consisted of a
    general overview  of  the  AgSTAR  Program,   methane
    recovery technologies,   anaerobic  biology,  odor  control,
    water quality benefits, project  development, and a field tour
    of a commercial farm operating a covered lagoon biogas
    system.
     Stacy Gettier leads workshop participants on a tour of an on-farm
                        digester facility.
>*  Expanded AgSTAR  services to  include  cooperative  or
    centralized   digester   assessments.       This   manure
    management strategy can provide opportunities for multiple
    farms.   Key factors influencing  multiple  farm  feasibility are
    herd sizes, manure management  method and distance from
    centralized digester site(s).   Typically,  digester  sites are
    located  near  some  large energy  user  or electric  utility
    gateway.   Site  examples  include  feed  mills,  prisons,
    rendering plants, substations, and other large users of heat
    and electricity.   Successful planning  of centralized digesters
    needs   to  include  assessment  of   technical,   financial,
    environmental,   and  organizational  elements  to  insure
    successful long-term operation.  The AgSTAR program has
    completed two  feasibility  assessments.    See   Regional
    Corner tor project details.

>V AgSTAR's Charter  Farm  Program is designed to assist in
    the  development  of biogas technologies  at commercial
    livestock  farms  to  demonstrate  a variation of appropriate
    technologies  in  key  livestock producing states.   Charter
    Farms  are available to livestock producers  and others for
    site visits on  an  appointment basis.   Operational charter
    farms already include dairy and swine farms in New York,
    Pennsylvania,  North  Carolina,  Illinois, Iowa  and  Oregon.
    Charter  Farms are  also in construction or planning phases
    in  Colorado, California, Wisconsin and Minnesota.  To make
    arrangements for a farm visit to "kick the tires"  and  talk with
    farm operators,  or to  apply as a  Charter Farm candidate for
    the 1999 construction season, call  the AgSTAR Hotline at
    1-800-95AgSTAR (1-800-952-4782).
2 • AGSTAR DIGEST, FALL 1998

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AgSTAR Support Corner:   AgSTAR Handbook & FarmWare
 ftBW
    AgSTAR  is pleased to announce completion of the first
    edition  of the AgSTAR Handbook --  a comprehensive
    "how-to" manual  for  developing  biogas systems  at
commercial  farms  throughout  the  United  States.    The
handbook  provides  a   framework  for   farms   that  are
considering   biogas  production  and  use  as  a  manure
management  option.   Using  the handbook, a  livestock
producer should be able to make a "go" or "no go" business
decision based on technology choice, operational ability, and
financial performance.

                                      The handbook is
                                 organized    according
                                 to the  two  stages  of
                                 biogas         project
                                         development:
                                 feasibility  assessment
                                 and    implementation.
                                 The         feasibility
                                 assessment  chapters
                                 provide  guidance on
                                 screening  for  project
                                         opportunities,
                                 selecting a  gas use
                                 option,           and
                                 conducting       site-
                                 assessments       to
                                 identify     technically
appropriate  and cost-effective biogas recovery  options.  The
implementation  chapters  detail the steps  in   putting  project
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                  Handbook
plans  to  work.   Chapters  include:  selecting a  developer;
obtaining   project   financing;   complying   with   permitting
requirements; and designing and constructing the system.

    The  appendices  of  the  handbook provide  supporting
information including profiles of working digesters  throughout
the  U.S.,  NRCS  and DOE  contacts,  the  NRCS  Interim
Practice Standards, and  a  list  of  industry  contacts.   In
addition,  the   appendices  include  installation   disks and
manuals  for   the  FarmWare  and   RateVision  software
programs.

    FarmWare is  a user-friendly decision support computer
program that helps livestock producers  determine  whether a
methane recovery system can be profitably integrated into a
farm's existing or planned  manure management system.  The
software analyzes  the  financial  performance of a methane
recovery system including the  installation costs and benefits
from  on-farm  biogas  use.   FarmWare's reporting features
include a Summary Report that can be  presented to potential
project financiers, contractors,  and developers.   RateVision
(version 1.0)  is a software  program  designed to analyze
electricity rate  schedules in  relation  to  farm  energy load
profiles.   RateVision  files can  be imported  into  FarmWare
allowing for a detailed analysis  of  rate schedules  in  the
financial evaluation of a methane recovery system.

    To order a copy of the AgSTAR Handbook and the
latest software programs, please call the AgSTAR Hotline at
1-800-95AgSTAR (1-800-952-4782).
Environmental Corner:   Manure  Odors Raising  a  Stink
     anure-related odors have been attracting a great deal
     of attention  over the past few years, pitting the public
     against the livestock producers.  While the detection of
odor from livestock facilities varies  from nose to nose, there
is  considerable concern  in  some  parts  of  the country that
manure-related odors will intensify  with the continued trend
toward  larger confined operations.  In addition, many  believe
that  increased complaints  regarding livestock  odors  are
inevitable as more people move to  the country from cities to
suburbs.

    Seasonal  or  chronic   odor   events  from    manure
management systems are indicative of a  biological  imbalance
within   the  system.    Biological  imbalances  have  many
potential causes, ranging  from system design and sizing to
operational  parameters.     Regardless  of  the cause,  the
resulting biological imbalance leads to only partial digestion
of  the incoming waste stream.  Inhibiting  complete anaerobic
                                                             digestion   and   methane  production  allows  intermediate
                                                             odorous compounds to form and escape into the surrounding
                                                             air potentially creating  an  odor.   Designing and  operating
                                                             manure  management  systems  to   promote  methanogenic
                                                             biological activity can effectively reduce odorous compounds.
                                                             Methane   bacteria   degrade   most   odiferous   organic
                                                             compounds  producing  methane  and  carbon dioxide, which
                                                             are  odorless.  Promoting anaerobic digestion and  methane
                                                             production  reduces  odorous  compound  concentrations.   In
                                                             addition, as a secondary benefit, methane is produced and
                                                             can then be used as an on-farm energy source.

                                                                 Numerous  studies  have  shown that  digested manure
                                                             emits  fewer  odors  than undigested  manure.   Pain  et al.
                                                             (1990) quantified these results showing that up to 92% of the
                                                             odor  associated  with   pig  manure  can  be reduced by
                                                             anaerobic digestion.  A summary of these results is  shown  in
                                                             the table below.
Odor concentration (odor units / m3 air) following spreading of pig slurries on grassland
Days in Storage
5
20
Farm A
Undigested
611
219
Digested (% Reduction)
142(77%)
18(92%)
FarmB
Undigested
1101
177
Digested (% Reduction)
223 (80%)
38 (79%)
Source: Pain, B.F., T.H. Misselbrook, and C.R. Clarkson. 1990. Odour and ammonia emissions following the
spreading of anaerobically digested pig slurry on grassland. Biol. Wastes 34: 259-267.
                                                                                       3 • AGSTAR DIGEST, FALL 1998

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      Showcase  Corner:  AgSTAR Partner Farms
      Craven Farm

      n December  1996, Jeff Craven, owner/operator of Craven
      Farms in Cloverdale, Oregon, completed the installation of a
      methane recovery system at his 650-cow freestall dairy.  The
    heated plug flow digester is an in-ground concrete structure that
    measures 140 feet long, 30 feet wide, and 12 feet deep.  The
    digester is sized to treat manure from up  to  1,000 milk cows,
    and is covered  by an  inflatable and impermeable vinyl/plastic
    material.  Manure from the freestall barns is scraped once a day
    into a collection  tank  for mixing.  From the tank, the  manure is
    pumped into the digester.

        Under the  anaerobic  conditions within  the digester,  the
    manure is broken  down to produce  biogas and a  nutrient-rich
    effluent.  The biogas, which is  primarily methane, is  collected
    under the digester cover and pumped to  two engine  generator
    sets, which  started  running on  biogas January 1997.   The
    engines produce approximately 60 kW of electrical energy each.
    All of the power produced is  sold directly to the  local utility
    company as a source of green power for their generation mix.

        To   maintain   an   optimum   digester   temperature   of
    approximately 100°F, a  network of water-heated  pipes  run
    within the digester.  The water is heated and recirculated  into
    the  digester  from a heat exchanger  system used to  cool  the
    engine generator sets.   By  Summer 1997, a plumbing system
               Craven Farms'Plug Flow Digester.
                  The digester is 140 feet long.
will be installed so that hot water from the engine cooling system
can also be supplied to the milking parlor.

    Once  the  manure  has exited  the  digester,  the  solids
(Fibers) are separated from the liquid fraction.  Separated  solids
are sold  to a local potting soil  company and  liquid  effluent is
stored in a lagoon and land applied.

    The  methane  recovery system  at  Craven  Dairy has
produced  revenues  from  electricity  and  fiber  sales,  while
providing  the  farm  with an  environmentally  sound  manure
management strategy.
    "Aside from the environmental benefits, the
    most important aspect of the digester for me
    is that it is not nearly as complicated as I had
    anticipated.   It doesn't  take a chemist to run
    it.    The system  is simple  and  just  a basic
    biological process."

           Jeff Craven,  Little Nestucca Watershed,
             Cloverdale, OR
                                                               Separated solids from Craven Farm's Plug Flow Digester
                                      Craven Farms' engine room
4 • AcSTAR DIGEST, FALL 1998

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 Martin Farm
     Harry and  Debbie Martin are raising hogs in southern
     Virginia at their 600 sow farrow to feeder pig hog facility.
     They installed a covered anaerobic lagoon in fall 1993.
 Unfortunately, the cover began to develop  problems with gas
 movement due to  rainwater accumulation by the  following
 year.  In  1996  the  Martins requested technical support from
 the Tennessee Valley Authority  and  the AgSTAR  Charter
 Farm Program to address the problems.
Rainwater accumulation on the previous cover at Martin Farm

The covered anaerobic lagoon, designed according to NRCS
Interim Standard No. 360 measures 124' by 124' by 22' deep.
The constant volume primary lagoon receives manure from
recycle flush tanks controlled by electronic timers.  Buildings
are flushed 3-8  times/day  with recycled  water  from  a
secondary storage lagoon.  Methane is produced as the liquid
waste stream is  treated and is captured by a new modular
cover  system,  which floats on the surface of  the  primary
anaerobic lagoon. The treated effluent from the new covered
lagoon overflows  into  the storage lagoon and  is used  for
recycle water and seasonal fertilization.

Six new modular covers  were developed  with AgSTAR
technical  assistance and factory-built by Engineered Textile
Products, of Mobile, AL,  an AgSTAR  Ally.  The  Martins
installed  the  lagoon  covers,  built  from Seamens  XR-5
material, over a three-day period April 1997.
  "The  technical  support  that I  have
  received    through    the    AgSTAR
  Program  has been tremendous.  First,
  AgSTAR   and  the Tennessee  Valley
  Authority helped me replace the cover
  on  my  lagoon.    Now,  AgSTAR  is
  helping me  to maximize  the benefits
  of  my biogas  recovery  system  by
  providing    me    with    innovative
  options."
        Harry   Martin,   Martin  Farm,
           South Boston,  VA
Methane generated in the covered lagoon digester is pumped
from  under the floating  cover with a vacuum pump.   The
biogas  flows   from  the  digester,   through   a  550-foot
underground gas pipeline, into an engine generator.   The
electrical production  system consists of a 6 cylinder  Chrysler
internal  combustion engine coupled to  a 25 kW, single-phase
induction generator.   The unit generates in parallel with the
Virginia Power  Company.  The farm also has a low cost flare
to  combust biogas during engine down times or periods  of
excessive gas  production. Biogas production varies between
8,000 and 14,000 ft3 per day,  winter versus summer, due  to
changes in lagoon temperature.  Low winter gas production
limits engine use.

Providing  heat to young  piglets may be another benefit of the
Martin's  methane  recovery   system.    The  Martins are
considering adapting the  farrowing buildings to circulate hot
water produced by  biogas and the engine system  through
heat mats.  This new technical development, first  applied at a
Partner Farm in North Carolina, can increase financial returns
by reducing heat lamp and propane use for very little cost.
Direct use of heat as hot water appears to  have a higher
value when used in farrowing crates than as previously used
in hot air applications.

The Martins are pleased  with their methane recovery system.
It has helped them realize the benefits of controlling odor and
energy   production,  while   being   recognized  for  their
environmental  stewardship through EPA's AgSTAR Program.
           Installation of new cover at Martin Farm
 To arrange  a visit to Martin or
    Craven Farms,  contact the
         AgSTAR Hotline  at
           1-800-95 AgSTAR
           (1-800-952-4782)
                                                                                   5 • AcSTAR DIGEST, FALL 1998

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Other Regional  Activities  Corner
   n  addition to the Craven and Martin Farm system, other
   AgSTAR   Partner   farms  are   in   either  planning,
   construction,  or operational phases of their systems.  A
few of these farms are highlighted below:
A A  Dairy. Candor. NY.  Bob Aman and his family have
over  500  milking  cows  with  scraped  freestall  manure
collection.  A plug flow digester was constructed  (designed
for  1,000 cows) and started-up  in fall of 1997. Biogas fuels
a boiler to  heat the  digester and provide heat to  the dairy.
In early 1998 AA Dairy purchased  and rebuilt a  used 120
kW  engine generator to produce electricity for farm use and
sale.   The engine  will  provide   1,200  -  2,000  kWh  of
electricity per day and  is scheduled to  go on-line by June
1998.

AA  Dairy is separating digested solids for  sale  as fiber.
Separated  liquids are stored  for irrigation over cropland.
About his digester system, Bob Aman  said, "We're really
excited about this ultimate recycling project."

Apex Pork, Galesbum,  IL  Glenn and Roger Saline own
and  operate an  8,600 head  finishing farm in  west-central
Illinois.   Nine buildings  are  equipped  with  pit  recharge
manure collection.  The storage basin has  been prone to
seasonal  odor  events.   Therefore,  the  farm installed  a
prototype earthen, heated, "mixed"  covered  lagoon as part
of  the  farm's  odor  control   strategy.    After  digestion,
deodorized effluent  will flow  to  the storage basin prior to
land application.   The digester will  stabilize  odor-producing
compounds  and  the  additional heat entering  the storage
lagoon  should  increase  its  biological  performance over
time.   The digester is  complete and biogas production is
expected by early June.  Gas is used in a boiler and flare
setup.
 Example of AgSTAR Environmental Stewardship Certificate

Boland Farm.  Williamsburg. IA.  Gary Boland, a fourth
generation  farmer,  his wife Annette and four children  live
about a mile from Williamsburg,  Iowa, a growing town  of
2,500 people.  The Bolands  operate two separate farm
sites,  a finishing operation with a deep pit system and  a
nursery with a pull plug and variable depth storage lagoon.
Since the Bolands built the lagoon two years  ago they have
observed that the odor is stronger than they would like it to be.
Because the Bolands want to do everything possible to be good
neighbors, they installed a cover over the 150' by 130' lagoon to
capture  and flare off methane  for odor control.   This  system
does not require heat and is strictly for odor control.  Wintertime
gas production  will be almost zero.   The cover was installed
early  May  1998  and  is operational.   Total installed cost was
about $15,000.
Colorado  Pork.  Prowers.  CO.    Gary  Swanson,  General
Manager  and   part  owner  of  Colorado  Pork  has  begun
construction on  a  new 5,000  sow farrow to wean farm.   All
buildings will operate  on a pull  plug  manure  handling system.
The farm's  objective is to build an environmentally friendly waste
management system that is sustainable  both  from  an energy
and  nutrients  recycling  standpoint.    A  heated complete  mix
digester for manure treatment  is planned as an integral part of
the farm's   manure management.    The  decision  to  build  a
digester was made after comparing the cost of a 20-day heated
mixed digester to the  cost of a  lined  treatment lagoon built to
meet  NRCS guidelines.   The mixed digester was found to be
almost the  same cost  as the  lined treatment lagoon, if not less
expensive.   There also  is a return on investment from energy
cost  savings,   estimated   at   $67,000/year  electric    and
$29,000/year propane  savings.  Farm  and digester construction
is  scheduled for completion  h December 1998.  Digester start-
up should  begin Fall  1999,  when the farm is three  quarters
populated.


Doe/man  Dairy.  Rochester.  WA.    Fred  Colvin  of  Hank
Doelman Dairy,  requested AgSTAR  assistance  to evaluate  the
1,200  cow  dairy  and  surrounding   dairies  for  a centralized
digester system.  The proposed project is under consideration
and may involve up to 6 dairies totaling 3,000 cows.  The project
consists of  3 phases.  The first phase  will begin construction on
a  1,500 cow  digester in Spring  1999.  The conslruction of
additional digester modules  during phases 2  and 3 is under
consideration to accommodate the remaining 1,500 cows.


Freund Dairy. East Canaan.  CT.  Matt and  Ben Freund milk
200  cows   in  a  freestall  barn  with  tractor   scrape  manure
collection.   The dairy  pastures cows 16 hours a day from late
spring until  early fall and cows are in the barn the  rest of  the
year.   A small  "drive-in" plug flow digester was completed and
started up in Fall 1997. The driving force  behind the  project was
the desire  to upgrade  the waste management system,  better
manage  the  solids  in   the   manure   and  produce  usable
byproducts.   Biogas is used  as a fuel  source in a boiler  that
generates heat  for the  digester  as  well as  for  on-farm  use.
Excess  biogas not  used  in either application is flared.  Freund
Dairy  plans to use hot water  to heat a  greenhouse to supply
fresh  produce  for the  family's  farm  store.    The  farm  is
considering  accepting  some manure from neighbors during  the
pasturing period  to maintain constant gas production for fueling
a small co-generation unit.
6 • AcSTAR DIGEST, FALL 1998

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