Environmental Technology
Verification Program
Environmental and Sustainable
Technology Evaluations
Test/QA Plan for
Verification of
Anaerobic Digester for Energy
Production and Pollution Prevention
ET/ET/ET/
TEST/QA PLAN
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for
Verification of
Anaerobic Digester for Energy
Production and Pollution Prevention
January 23, 2007
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A2 TABLE OF CONTENTS
Section Page
A PROJECT MANAGEMENT
Al Title Page 1
A2 Table of Contents 2
A3 Distribution List 6
A4 Verification Test Organization 8
A5 Background 13
A6 Verification Test Description and Schedule 14
A7 Quality Objectives 18
A8 Special Training/Certification 18
A9 Documentation and Records 19
B MEASUREMENT AND DATA ACQUISITION
Bl Experimental Design 20
B2 Sample Collection 26
B3 Sample Handling and Custody Requirements 27
B4 Laboratory Reference Methods 28
B5 Quality Control Audits and Requirements 29
B6 Instrument/Equipment Testing, Inspection, and Maintenance 30
B7 Instrument Calibration and Frequency 30
B8 Inspection/Acceptance of Supplies and Consumables 30
B9 Non-Direct Measurements 30
BIO Data Management 31
C ASSESSMENT AND OVERSIGHT
Cl Assessments and Response Actions 33
C2 Reports to Management 35
D DATA VALIDATION AND USABILITY
Dl Data Review, Validation, and Verification Requirements 36
D2 Validation and Verification Methods 36
D3 Reconciliation with User Requirements 36
E REFERENCES 37
Appendix A Reference Analytical Methods 38
Appendix B Verification Data Sheets 39
Appendix C Data Checklist 44
Appendix D System Schematics 45
Appendix E Test/QA Plan Addendum 53
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Page
List of Figures
Figure 1 Organization Chart 9
Figure 2 Heat Exchanger and Cooker 17
List of Tables
Table 1 Reference Analytical Methods 21
Table 2 Approximate Costs Associated with Each Testing Task 22
Table 3 Measurements Used to Calculate Each Performance Parameter 26
Table 4 Summary of Data Recording Process 32
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ETV Environmental and Sustainable Technology Evaluations
Test/QA Plan for Verification of
Anaerobic Digester for Energy
Production and Pollution Prevention
January 23, 2007
VENDOR APPROVAL:
Name
Company
Date
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A3 DISTRIBUTION LIST
Vendor
David Wagner
Wagner Anaerobics
363 Ridge Ave.
State College, PA 16803
EPA ETV Director
Teresa M. Harten
U.S. Environmental Protection Agency
National Risk Management Research Laboratory
26 West Martin Luther King Drive
Cincinnati, Ohio 45268
EPA QA Officer
Scott Jacobs
U.S. Environmental Protection Agency
National Risk Management Research Laboratory
26 West Martin Luther King Drive
Cincinnati, OH 45268
EPA Project Manager
Dr. John R. Haines
U.S. Environmental Protection Agency
Land Remediation and Pollution Control Division
National Risk Management Research Laboratory
26 West Martin Luther King Drive
Cincinnati, Ohio 45268
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Stakeholders who conducted the site visit
Steve Wittmann
Sr. Client Services Manager
RMT, Inc.
744 Heartland Trail
Madison, WI 53717
William A. Johnson
Manager, Agricultural Compliance
Alliant Energy
2777 Columbia Dr.
Portage, WI 5 3 901
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Stakeholders who reviewed the QA/ Test
Plan
William A. Johnson
Manager, Agricultural Compliance
Alliant Energy
2777 Columbia Dr.
Portage, WI 53901
John Menke
California State Water Resources Control
Board
Dr. Matt Smith
USDA
Building 306, Room 109 BARC East
Beltsville, MD 20705-2350
Additional Stakeholders
Charlotte White 202-564-8559 white. charlotte@epa.gov
GaryObleski 717-772-8945 gobleski@state.pa.us
William Boyd 336-370-3334 william.boyd@gnb.usda.gov
Gregory Beatty USEPA 202-564-0724 beattv.gregory@epa.gov
David Wagner Wagner Anaerobics 363 Ridge Ave. State College, PA 16803
814-861-4549 off. 814-883-3168 cell davidwagner@adelphia.net
David McElhaney 724-544-2391 dmcelhaney@allflexusa.com
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SECTION A
PROJECT MANAGEMENT
A4 VERIFICATION TEST ORGANIZATION
This verification test will be conducted under the auspices of the U.S. Environmental
Protection Agency (EPA) through the Environmental and Sustainable Technology Evaluations
(ESTE) and Environmental Technology Verification (ETV) programs. It will be performed by the
awarded contractor (to be determined), under contract with the EPA.
The day to day operations of this verification test will be coordinated and supervised by
contractor personnel, with the participation of the vendor, Wagner Anaerobics. This test will be
conducted at Zimmerman Farm in Pitman, Schuylkill County, Pennsylvania, following the
performance evaluation protocol developed by Dr. John H. Martin(1). The field component of
testing will be performed by contactor staff with assistance from the vendor and host site
organizations. Vendor representatives will operate their respective technologies throughout the
test unless they give written consent for the verification staff to carry out these activities. Quality
assurance (QA) oversight will be provided by the contractor's Quality Manager, and by the EPA
Quality Manager at his discretion. The organization chart in Figure lisa suggested functional
description of the responsibilities of the organizations and individuals associated with the
verification test. Roles and responsibilities are defined further below.
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Contractor
Management
Contractor
Quality Manager
John Haines
EPA
Project Manager
Contractor
Verification
Testing Leader
Zimmerman
Farm
Host Site
Scott Jacobs
EPA
Quality Manager
Contractor
Verification
Technical Expert
Anaerobic Digester
Vendor
Representatives
Site
Technical Staff
Figure 1. Organization Chart
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A4.1 Contractor
Verification Testing Leader. This person will have overall responsibility for ensuring that
the technical, schedule, and cost goals established for the verification test are met. Specifically,
he will:
• Assemble a team of qualified technical staff to conduct the verification test.
• Direct the team (contractor, EPA, and host site staff) performing the verification test in
accordance with the test/QA plan.
• Ensure that all quality procedures specified in the test/QA plan and in the ETV Quality
/o\
Management Plan^; (QMP) are followed.
• Prepare the draft and final test/QA plan, verification reports, and verification
statements.
• Revise the draft test/QA plan, verification reports, and verification statements in
response to reviewers' comments.
• Respond to any issues raised in assessment reports and audits, including instituting
corrective action as necessary.
• Serve as the primary point of contact for vendor representatives.
• Coordinate distribution of the final test/QA plan, verification reports, and statements.
• Establish a budget for the verification test and manage staff to ensure the budget is not
exceeded.
• Ensure that confidentiality of sensitive vendor information is maintained.
• Maintain communication with EPA's technical and quality managers.
Contractor Management. This individual will provide technical guidance and support for
the verification testing program. Specifically, this person will:
• Support the testing leader in preparing the test/QA plan and organizing the testing.
• Review the draft and final test/QA plan.
• Review the draft and final verification reports and verification statements.
• Ensure that necessary contractor resources, including staff and facilities, are
committed to the verification test. Ensure that confidentiality of sensitive vendor
information is maintained.
• Support the testing leader in responding to any issues raised in assessment reports and
audits.
• Facilitate a stop work order if the contractor or EPA QA staff discovers adverse
findings that will compromise test results.
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Contractor Technical Experts will work with the verification partners to conduct the
testing of the anaerobic digester. Contractor staff will be on-site at the host site at various times
throughout the verification test. The responsibilities of the technical staff will be to:
• Assist the host site in any and all aspects of performing the verification test as
described in the test/QA plan.
Contractor Quality Manager. The contractor's Quality Manager will:
• Review the draft and final test/QA plan.
• Conduct a technical systems audit once during the verification test.
• Audit at least 10% of the verification data.
• Prepare and distribute an assessment report for each audit.
• Verify implementation of any necessary corrective action.
• Request that contractor management establish a stop work order if audits indicate that
data quality is being compromised.
• Provide a summary of the QA/QC activities and results for the verification reports.
• Review the draft and final verification reports and verification statements.
• Assume overall responsibility for ensuring that the test/QA plan is followed.
A4.2 Vendors
The responsibilities of the vendor representatives are as follows:
• Review the draft test/QA plan.
• Approve the test/QA plan prior to test initiation.
• Provide their digester and associated operating equipment for evaluation during the
verification test.
• Provide all other equipment/supplies/reagents/consumables needed to operate their
monitors for the duration of the verification test.
• Operate the digester throughout the test, and provide written consent and instructions
for contractor staff to carry out sample collection and data system download activities.
• Review the draft verification report and statement.
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A4.3 EPA
EPA's responsibilities in the ETV and ESTE programs are based in part on the
requirements stated in the "Environmental Technology Verification Program Quality
Management Plan" (EPA QMP)^. The roles of the specific EPA staff are as follows:
EPA Quality Manager. The EPA's Quality Manager will:
• Review the draft test/QA plan.
• Perform at his/her one external technical systems audit during the verification test.
• Notify the contractor management of the need for a stop work order if the external
audit indicates that data quality is being compromised.
• Prepare and distribute an assessment report summarizing results of the external audit.
• Review draft verification reports and statements.
Dr. John Haines is EPA's project manager for this ETV-ESTE test. Dr. Haines will:
• Review the draft test/QA plan.
• Approve the final test/QA plan.
• Review the draft verification reports and statements.
• Oversee the EPA review process for the verification reports and statements.
• Coordinate the submission of verification reports and statements for final EPA
approval.
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A5 BACKGROUND
The ETV-ESTE Program conducts third-party verification testing of commercially
available technologies that improve the environmental conditions in the U.S. A stakeholder
committee of buyers and users of such technologies guided the development of this test on
anaerobic digesters.
Large scale animal agriculture in the United States produces manures in excess of one
billion wet tons per year. This waste is commonly spread upon cropland both as a fertilizer and as
a disposal mechanism. In many cases the available land is simply unable to absorb the quantities
of nitrogen and phosphorus applied, leading to the potential for nutrient pollution of surface and
groundwater. As a result of this activity, water quality and air quality are degraded throughout
the nation. In fact, the three most common causes for listing waters as impaired are nutrients,
sediments, and pathogens, all of which are heavily associated with manure land application at
Concentrated Animal Feeding Operations (CAFOs). In fact, non-point source pollution from
Animal Feeding Operations (AFOs) is listed as the leading cause of impairments in the nation's
freshwater rivers and streams. Approximately half of the impaired rivers and streams in the U.S.
are believed to be affected by animal feeding operations^. Development of commercial
technologies that can treat the waste from such operations and recover value from it is highly
desirable. In all cases, agricultural producers must do something with the manure produced by
their operations and any process which reduces costs and/or generates a revenue stream is
desirable.
Anaerobic digestion of livestock manures under controlled conditions to produce biogas (a
mixture of methane and carbon dioxide) can provide livestock producers with the opportunity to
increase net farm income, typically by using captured biogas to generate electricity for on-site
use, or delivery to a local electric utility, or both. This biogas utilization approach also provides
an opportunity to utilize waste heat captured from an engine-generator set to reduce on-farm
demand for conventional fuels (e.g., fuel oil and propane) for water and space heating. Direct
combustion of biogas for on-farm water and space heating in place of conventional fuels also is
an option. An added benefit of anaerobic digestion of livestock manures is that potentially
negative impacts of these wastes on air and water quality are reduced. This includes but is not
limited to reducing the emissions of methane, a greenhouse gas with approximately 21 times the
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heat trapping capacity of carbon dioxide, when manure decomposes anaerobically under
uncontrolled conditions. In addition, producing, capturing, and using manure biogas as a fuel
reduces emissions of carbon dioxide from fossil fuel combustion to generate electricity or produce
heat.
The steady development of biogas systems and an awareness of their merits has produced
an increased level of interest by livestock producers in manure biogas production and broadened
their use from mostly dairies to a variety of waste streams. Concurrently, a number of different
system designs have emerged with claims about performance superiority as the number of system
developers has increased. To facilitate comparison between systems and verify performance, a
standard evaluation protocol*^ has been developed. This study is based on that protocol, sections
of which have been excerpted as appropriate.
A6 VERIFICATION TEST DESCRIPTION AND SCHEDULE
This verification test will conduct a third-party performance evaluation of a commercially
available anaerobic digester built at the Zimmerman Farm, a 600 acre farm near Pitman, PA. The
farm has two livestock operations: a 1,000 head cattle-feeding operation and four poultry houses
with a total of 120,000 chickens for the broiler market. The anaerobic digester has been designed
by Wagner Anaerobics to utilize irregular mixtures of both waste streams, incorporating thermal
pre-treatment of the mixed waste, mixed in a waste pit, to increase digestibility with chemical
treatment and solids separation. This study will evaluate the performance of the digester for one
year; starting after 5 HRTs (hydraulic retention times) are completed during the startup phase of
the digester. The objective of the study is to verify digester performance in the areas of pathogen
reduction, waste stabilization and biogas production. Due to the prototypical nature of the system,
an economic analysis will not be conducted.
A6.1 Site and Facility Summary
The site for this study is Zimmerman Farm; a 600 acre farm located in Schuylkill County,
near Pitman, Pennsylvania. The farm produces 120,000 chickens for the broiler market on a 7-
week cycle, and has a 1,000 head cattle herd, growing out feeder calves for the beef market. The
farm is currently not operating under a nutrient management plan.
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The farm pastures young cattle, while older animals are fed in a slat-barn located next to
the digester. Cattle are also fed in pens and a loafing shed located below the slat-barn. Manure
from the pens and shed is scraped into a push-off pit where it is stirred and chopped by mixers,
combined with yard runoff from a storage tank and then pumped to a mixing pit which also
receives manure from the slat-barn. Poultry manure and occasionally swine manure from an
associated operation is added to the mixing pit, whose contents are stirred and chopped before
being pumped to the digester facility. Farm operations produce 6-8,000 gallons of manure slurry
per day, with a solids content of 7-14%.
Initial start-up of the digester in May 2006 was affected by a monensin-type growth
promoter used as an additive in the cattle feed, which inhibited methane production. The additive
has been removed from the feed, and the digester was cleaned to remove inhibited contents. The
digester facility will be re-started by January 2007.
The digester system was designed to allow the farm use of complex high-rate digestion
systems by remotely linking operators and service technicians via a SCADA (Supervisory Control
and Data Acquisition) system. The facility (see system schematics provided by Wagner
Anaerobics in Appendix D) is a hybrid thermophilic system which uses 4 modular digester tanks
(coated steel insulated to R25, 15,500 gal nominal volume) operated in series. The first three
tanks are complete mix digesters with the final tank operated as a fixed-film digester. Each tank
is provided with a 200 gpm mixing system and steam injection to maintain temperatures in the
upper thermophilic region of 135-145° F (57-63°C). Other features of the system as given by
Wagner Anaerobics are:
• High temperature/pressure (300°F/50 psi) pretreatment of manure to increase digestible
fraction and reduce pathogens
• SCADA control system for remote monitoring of process activities and automatic dispatch
of service personnel in case of system component malfunction
• Use of geo-fabrics for solids separation and low moisture solids for export
• Use of phosphorous stripping for removing soluble phosphorous from manure stream
• Use of hose reel irrigation system for reducing crop water stress
• Use of closed systems for elimination of odors from treatment process and storage lagoons
• Storage tanks only handle solids-free digested liquids
• All manure is handled by irrigation pipeline to reduce field compaction by heavy slurry
tankers and tractors.
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Manure slurry pumped from the mixing pit (T-3, see schematics in Appendix D) is processed
by a Vogelsland grinder and pumped to a surge tank (T-4) which feeds a low-temperature heat
exchanger (HE-1) connected to a 2,000 L pressurized cooker (HE-2). The contents are heated to
300°F at a pressure of 50 psi for 45 minutes, then routed to a series of heat exchangers (HE-9,-10)
to recover excess heat before entering the first digester tank (D-l). Digested manure leaves the
system at the last digester where it is pumped (while injecting polyelectrolytes and aluminum
sulfate) into geo-fabric storage bags (AgBags, 30 cubic yards) designed to filter water from the
treated solids. Solids are left in the bag to dry to 50% moisture, while the liquid, stripped of
dissolved and suspended phosphorus, is pumped to a storage tank (T-7) for later field application.
Solids are stored on-site. Figure 2 shows a photo of the heat exchanger and cooker.
Biogas is collected from each digester and AgBag and stored in tank T-9. Hydrogen sulfide
(H2S) is removed from the gas before combustion using a stripping tower (T-l 1) with potassium
permanganate. The biogas is then compressed by a regenerative blower (BL-1) and burned in the
boiler and generator sets (GenSet 1 and 2); any untreated excess gas is consumed by flare (F-17).
The generators are equipped with both exhaust and water-jacket heat exchangers, with GenSet 1
providing 3-phase power for facility and farm use, while GenSet 2 provides single-phase power
for sale thru net-metering.
The SCADA system provides remote process control while collecting data on system
operation. Data collected includes:
• Temperature in each digester and process vessel
• Monitoring of parasitic loads by recording operating periods, volts and amperage of
pumps and cooker
• Liquid levels and valve positions
• Influent and effluent flows are recorded and totalized using Rosemont Model 8600
magmeters
• Biogas flow is recorded and totalized as used and at each digester using orifice flow
meters with Ashcroft differential pressure sensors.
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Figure 2. Heat exchanger and cooker.
A6.2 Verification Schedule
The verification test of the anaerobic digester will be conducted over a period of
approximately one year, beginning early 2007. Approximately every month a set of samples will
be sent to the third party laboratory for analysis. Samples must be collected at regular, periodic
intervals, so that a representative data set over an entire year can be obtained.
Within three months after the end of testing, a report will be drafted describing the
evaluation and performance of the tested technology. The report will be subjected to peer
reviews, and submitted to EPA for final signature. All documents will be submitted to EPA in
electronic (Microsoft Word and Adobe portable document format [pdf]) and hard copy formats.
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A7 QUALITY OBJECTIVES
This verification test will evaluate the performance of anaerobic digester technologies.
This will include a comparison of the inflow and outflow composition of the digester material, as
determined by standard laboratory reference methods. The quality of the reference measurements
will be monitored by the inclusion of blank, duplicate, and performance evaluation (PE) audit
samples. The PE audit samples will be analyzed using instruments or calibration standards that
are independent of those used for the rest of the reference analyses. These samples are meant to
independently confirm that the reference measurements are being performed correctly to produce
accurate results. Control limits on the duplicate and PE samples are given in Section Cl.
A8 SPECIAL TRAINING/CERTIFICATION
Documentation on training related to standard analytical chemistry methodology is to be
maintained for applicable contractor, host site, or commercial laboratory technical staff in training
files at the respective locations. The contractor Quality Manager will verify the presence of
appropriate training records prior to the start of testing. If the vendors request that contractor or
site staff operate and maintain their digesters during the verification test, the vendors will be
required to train the those staff prior to the start of testing. The contractor will document this
training with a consent form, signed by the vendor, which states which specific staff have been
trained to operate their digester.
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A9 DOCUMENTATION AND RECORDS
The records for this verification test will be contained in this test/QA plan, the protocols,
chain of custody forms, laboratory record books (LRB), data collection forms, electronic files
(both raw data and spreadsheets), and the final verification report. All of these records will be
maintained in the Verification Testing Leader's office during the test and will be transferred to
permanent storage by the contractor at the conclusion of the verification test. All contractor
LRBs are to be stored indefinitely, either by the Verification Test Leader or contractor's
management. EPA will be notified before disposal of any files. The results from the reference
measurements made by the host site technical staff will be submitted to the contractor within five
business days of making the measurement or obtaining the results of the analyses. Section BIO
further details the data recording practices and responsibilities.
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SECTION B
MEASUREMENT AND DATA ACQUISITION
Bl EXPERIMENTAL DESIGN SUMMARY
This verification test was designed to establish metrics for the Wagner digester that allow
comparison to other systems and waste streams. Data will be generated from influent and effluent
waste samples, gas production and utilization, and the anaerobic digester operating conditions
over a one year period. Influent samples and effluent samples will be collected at a regular
interval and analyzed for key parameters that show the performance of the digester. Table 1 lists
the parameters to be determined, and the analytical methods, sampling frequency, sample type,
number of samples per sampling event, and total number of sampling events for each parameter.
Following the AgSTAR protocol(1), biodegradibility of the raw and cooked manures will be
measured with one sampling event at Month 3. Biogas composition measurements will be made
on site and samples will be collected for laboratory analysis of methane and carbon dioxide.
Finally, the digester operating temperature and hydraulic retention time (HRT) will be recorded
monthly, based on measured effluent/influent flow rates.
The assumed cost for this test is $140,000. This funding will be spent on the test
planning, sampling, sample analysis and shipping, quality assurance, audits, data analysis, report
writing, and test coordination and logistics. A breakdown of these costs is shown in Table 2.
This cost breakdown assumes an approximate sampling event cost of approximately $3.2K, for all
influent, effluent and gas analyses. Therefore, 12 evenly spaced sampling events will be
conducted at roughly one month intervals. Sampling events will be conducted by a contract staff
member at the host site.
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Table 1. Reference Analytical Methods
Parameter
Total Solids
TVS
TVA
Fixed Solids
COD
NH3-Nitrogen
Total
Kjeldahl
Nitrogen
Total
Organic
Nitrogen
Total Phosphorus
Dissolved Ortho
Phosphate
Total coliforms
Total strep.
Salmonella spp.
M. avium
paratuberculosis
pH
NPK Ratios plus
Total Carbon
Manure
Biodegradability
Gas Composition
Method
EPA Method 160.3;
Date issued: 02/0 1/1 999
EPA 160.4; Date issued:
02/01/1999(total volatile
solids)
STM(2005) 5560C
(total volatile acids)
Determined by
difference b/n TS and
TVS
EPA Method 04 10.4
(Colorimetric); Date
issued: 08/01/1993
EPA Method 0350.1
(Automated
Colorimetry); Date
issued: 1993
EPA Method 3 5 1.2
(Total Kjeldahl
Nitrogen-1993)
Determined by
difference b/n NH3-N
andTKN
EPA Method 365.4
EPA Method 365.3
STM(2002) Multiple
Tube9221A-C15tube-
MPN
STM(2002) Multiple
Tube 9230A-B 15 tube
MPN
STM(2002) Multiple
Tube 9260D MPN
NADC or Cornell
methods (Stabel 1997)
EPA Method 150.1
Perm State Ag. Lab
Standard Manure Test 1
Non-standard
CH4 and CO2 ASTM
D1945;
Sampling
Frequency
Monthly
Monthly
Monthly
Monthly
Monthly
Quarterly
Quarterly
Quarterly
Quarterly
Quarterly
Quarterly
Quarterly
Unknown
Unknown
Monthly
Quarterly
Months
Quarterly
Sample Type
Influent and effluent
composites
Influent and effluent
composites
Influent and effluent
composites
FromAVGofTS
and TVS results
Influent and effluent
composites
Influent, filtrate, and
effluent composites
Influent, filtrate, and
effluent composites
FromAVGofTKN
and NH3 results
Influent, filtrate, and
effluent composites
Influent, filtrate, and
effluent composites
Influent and effluent
composites
Influent and effluent
composites
Influent and effluent
composites
Influent and effluent
composites
Influent, filtrate and
effluent composites
Solids Composite
Raw and cooked
manure
From Gas Flow
meter
Samples
Analyzed
Per Event
4
4
4
4
4
6
6
6
6
6
2
2
1
1
2-3
1
2
3
Total Sampling
Events
13
13
13
13
13
13
13
13
13
13
5
5
13
5
1
5
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Table 2. Approximate Costs Associated with Each Testing Task
Task
Test planning and setup
Sampling
Sample analysis and shipping/maintaining real time
measurement records
Quality assurance
Audits
Data reduction and analysis
Report writing
Test coordination and logistics
Total
Cost (US$)
5K
24K
56K*
5K
5K
15K
15K
15K
140K
The following sections describe the evaluations that will be conducted for each of the
digester performance parameters.
Bl.l Waste Stabilization
Using the measured mass flow of the influent and effluent streams along with the
measured concentrations of the Table 1 parameters, digester performance will be determined by
calculating a material balance for the system waste streams. Following guidelines given in
Section B2, composite samples of the influent (at T-4, see Appendix D) and effluent (at D-4) will
be collected monthly and analyzed for Total Solids (TS), Total Volatile Acids (TVA), Total
Volatile Solids (TVS), Chemical Oxygen Demand (COD), Fixed Solids (FS) and pH. Every
quarter month those samples will also be analyzed for Total Kjeldahl Nitrogen (TKN), Total
Phosphorus (TP), Ammonia Nitrogen (NHs-N) and Organic Nitrogen (ON). The degree of waste
stabilization will be reported as differences between the influent and effluent of these measured
parameters. AGBAG performance will be measured monthly by composite sampling fresh filtrate
(at VA-10 in Appendix D) and analyzing for Orthophosphate (OP), TP, and NH3-N. TS, TVS,
COD, FS and pH will be measured quarterly. Dried solids will also be analyzed quarterly by
composite for NPK ratio (ratio of nitrogen, phosphorus and potassium). Prior to beginning the
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study, a complete suite of samples and parameters will be analyzed as a performance evaluation
of the selected reference laboratory, using actual digester samples as the spike matrix.
B1.2 Biodegradability
Given the farm's manure mix, and since reduction of manure refractory fraction is an
integral part of this system, composites of raw manure (at T-4) and cooked manure (at P-2) will
be sampled at month 3. Samples will be used in long-term bench tests as outlined in the AgSTAR
protocol^. Tests will be conducted at temperatures approximating the digester average
temperature and analyzed for TVS concentration at Days 15, 30, 45 and 60. Complete details of
this test method will be provided by consultation with AgSTAR representatives.
B1.3 Pathogen Reduction by Inference
The potential pathogen reduction of the system will be measured by quarterly sampling of
the influent (T-4) and effluent (D-4) for enteric bacteria. Total coliforms and fecal streptococcus
will be used as indicators of pathogen reduction, quantified as per Table 1. Assays forM avium
paratuberculosis and Salmonella spp will be conducted as resources allow. Reductions in density
of pathogen indicator organisms will be reported in colony-forming units (CPU) per 100ml.
B1.4 Hydraulic Retention Time and Temperatures
Using influent/effluent flow data collected by the SCADA system, actual digester HRT
will be calculated monthly. Flow meters are new and have been factory calibrated, and cannot be
recalibrated during the study period. Vendor will check flow meter operation by recording pump
intervals with the SCADA system. Average temperatures for ambient air, digesters and
influent/effluent will be determined monthly using the SCADA system. The system uses
Rosemont RTD thermocouples whose accuracy will be checked monthly by the vendor using a
NIST-traceable dial thermometer (VWR's 37000-426 is suitable)
B1.5 Biogas Production
Total biogas production will be determined in this study using the vendor's orifice-type
meters linked to Rosemont Differential Pressure Sensors (Model 8600) located on each digester
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and the main biogas supply line. Due to cost restrictions, the vendor's gas flow meters will not be
calibrated. As a check on meter performance, biogas production will be estimated by utilization
parameters prior to beginning the study. A calibrated gas flow meter will be provided to the
vendor, who will install it on the outlet side of the compressor (BL-1). Monthly gas production
and study total will be reported under standard conditions (0° C and 1 atm) as per the AgSTAR
protocol(1).
B1.6 Biogas Composition
Biogas composition will be monitored monthly by the contractor using detector tubes
(Draeger or Gastec) for CC>2 and H^S. Measurements will be conducted before the biogas enters
the stripping tower (T-l 1). At least three replicate measurements will be made for each event,
Laboratory analysis of biogas composition by volume following ASTM 1945 will be
conducted quarterly for methane, CC>2 and Nitrogen. Duplicate samples will be collected at the
outlet of the stripping tower (T-l 1) in Tedlar bags or Summa canisters and shipped for analysis.
Ammonia and H2S will be measured by detector tube during these events, collecting three
replicate samples at the outlet of the tower (T-l 1). In addition, quarterly measurements of water
vapor will be made using detector tubes (Draeger or Gastec).
B1.7 Biogas Utilization
In this system, totalized biogas flow is collected at the main biogas supply line before
distribution to the boiler or GenSets. The SCADA system will be used by the vendor to
determine kW hours of electricity produced and boiler operation parameters. Beneficial use of
GenSet heat and exhaust will be measured by Btu meter or estimated from SCADA data by the
vendor contractor. GenSet operating hours will be recorded monthly from their respective
instrument panels by the contractor. Thermal conversion efficiency, on-line efficiency, average
GenSet output and average capacity utilization efficiency will be calculated by the contractor
monthly and on an annual basis when the study is completed, using the formulas given in the
AgSTAR protocol*^ equations la and Ib.
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B1.8 Reporting
Since the Wagner Anaerobics system in this test processes mixed manure from cows and
chickens, results for biogas production (under standard conditions) and electricity generated will
be reported as a function of the average daily loading of TVS and COD over the 12-month
evaluation period. Digester material balances will be reported in table format using a mg/liter
basis (except for pH), averaging influent and effluent parameters for the study period to determine
treatment efficiency, following the formulas given in Appendix A of the AgSTAR protocol.*^
Reductions in density of pathogen indicator organisms will be reported in colony-forming units
(CPU) per 100 ml. For the parameters tested, a comparison between whole effluent and separated
liquid on a mass per liter basis will be made. Following the Agstar protocol*^ and the examples
given in the Gordondale evaluation/3^ greenhouse gas reductions based on biogas production and
utilization combined with reduced demand for electricity generated by fossil fuels will be
estimated. Table 3 lists the performance parameters and the measurements used to calculate each.
Following procedures cited in the AgSTAR protocol,(1) reductions must be shown to be
statistically significant to at least the P<0.05 level, and confidence interval estimates must be
reported. Suspected outlier data shall be tested at P<0.05 using Dixon's method, as cited in the
protocol.*^
In addition, the data sheets found in Appendix B are to be filled out in full, as these forms
help produce estimates related to operation and maintenance costs. These data sheets record
important operational and logistical data that help characterize the operation of the anaerobic
digester system being tested.
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Table 3. Critical Measurements Used to Calculate Each Performance Parameter.
Performance
Parameter
Waste stabilization
Solids separation
Dried solids
Biodegradability
Pathogen reduction by
inference
Hydraulic retention time
and temperature
Biogas production
Biogas composition
Biogas utilization
Measurement Used in
Calculation
TS, TVA, TVS, COD, FS, pH,
TKN, TP, NH3-N, ON
OP, TP, NH3-N, TS, TVS, COD,
FS, pH
NPK
TVS
Total coliforms, fecal
streptococcus
Time from SCADA and temp
Flow rates from SCADA,
elapsed time
CO, H2S, CO2, N2, methane
kWh of electricity generated,
Btu of exhaust or genset heat
Influent concentration minus
effluent concentration
Whole effluent concentration
minus separated liquids
concentration
Mass fraction of N, P, K in dried
solids
Raw influent TVS concentration
minus Final TVS concentration
Influent minus effluent (colony
forming units per 100 mL)
System HRT: System
volume/influent volume; Actual
monthly influent/effluent
Totalizer volume/day
Component volume/Total gas
volume* 100
Watts of electricity + Converted
BTUs
B2 SAMPLE COLLECTION
As described above (Section A6), samples for the evaluation of digester performance will
be collected throughout the verification test and submitted to a third-party laboratory for analysis.
The samples will be collected following guidelines set in each standard reference method listed in
Table 1 and summarized in Section B4. The methods describe the appropriate sampling
containers, preservation techniques, and maximum holding times. This study will follow the
AgSTAR protocol, ^ using only ice or refrigeration to preserve samples. Aliquots of influent and
effluent will be transferred to appropriate sample containers, preserved as necessary, and
submitted to the independent laboratory for analysis. A sufficient amount of sample will be
collected to split as needed for nutrient, microorganism, and solids analysis. Given the inherent
variability in animal manures, care will be taken to ensure that all influent and effluent samples
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collected for analysis are representative of the average daily flow. While the most desirable
approach would be to collect 24-hour flow composite samples, it is recognized that this approach
generally is impractical for collection of livestock manure samples. Samples will be collected
from the sites given above in the Sections 1.1 to 1.3. Composites will be collected from piping
sample ports, using a series of at least six grab samples collected over a period of no less than one
hour and combined into a single composite sample. During the compositing process, grab samples
will be kept iced to enhance preservation. Composite samples shall be no less than 20 L (~5 gal)
and sub samples withdrawn for analysis shall be no less than one L (~ one qt). Where replicate
samples are being analyzed, two sub samples will be withdrawn and sent to the laboratory. If the
coefficient of variation for influent or effluent total solid concentrations exceeds 25 percent, more
frequent sample collection and analysis may be necessary.
B3 SAMPLE HANDLING AND CUSTODY REQUIREMENTS
Sample custody will be documented throughout collection, transport, shipping (if
necessary), and analysis of the samples, using standard forms used by the independent laboratory
for this purpose. Each chain-of-custody (COC) form summarizes the samples collected and
analyses requested. The COC form will track sample release from the sampling location to the
independent laboratory. Each COC form will be signed by an authorized person once that person
has verified that the COC form is accurate. The original COC forms will accompany the samples
and the shipper will keep a copy. Upon receipt at the laboratory, COC forms will be signed by
the person receiving the samples once that person has verified that all samples identified on the
COC forms are present. Any discrepancies will be noted on the form, and the sample receiver
will immediately contact the Verification Test Coordinator to report missing, broken, or
compromised samples. Copies of all COC forms will be delivered to the Verification Test
Coordinator, and maintained with the test records.
All anaerobic digester influent and effluent samples shall be immediately iced or
refrigerated following collection and delivered within 24 hours of collection for analysis. Sub-
samples shall not be acidified for preservation.
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B4 LABORATORY REFERENCE METHODS
Only analytical methods described in Methods for Chemical Analysis of Water and
Wastes, EPA-600/4-79-020 (U.S. Environmental Protection Agency, 1983)(3) or Standard
Methods for the Examination of Water and Wastewater, 21st edition (American Public Health
Association, 2005)(4) are acceptable unless it can be demonstrated that an alternative provides the
same degree of precision and accuracy. All analyses of influent and effluent samples shall be
performed by an analytical laboratory with certification to perform analyses of wastewater to
satisfy National Pollutant Discharge Elimination System (NPDES) reporting requirements or have
comparable certification. In the event that an analytical laboratory without the appropriate
certification (such as university research laboratory) is used, that laboratory must have an ongoing
quality assurance/quality control program that is comparable to such programs required for
certification. The laboratory used must have previous demonstrable experience in analyzing
samples with high solids concentrations, and duplicate analyses of individual samples shall be
performed for all parameters.
Table 1 of Section Bl lists the reference analytical methods that will be used for the
sample collection and reference analyses during this verification process. The collection of the
samples will be the responsibility of the contractor which may assign responsibility to either the
independent laboratory staff, or contractor staff. Results of the sample analyses will be provided
to the contractor within 14 days of sample receipt. The contractor will provide the EPA project
manager with all sample results within one week of receipt of the sample results from the
laboratory. All the standard analytical methods listed in Table 1 are attached in Appendix A.
B4.6 Data Collection
All meters used to measure biogas production and utilization, electricity generated,
engine-generator set hours, and waste heat beneficially utilized shall be calibrated or recalibrated,
if previously used, by the manufacturer prior to the beginning of each performance evaluation. In
addition, each meter shall have a manually non-resetable totalizer to avoid accidental data loss
and all meter readings shall be recorded at least during every sampling episode with the date and
time of the meter reading noted. In addition, a copy of the digester operator records shall be
obtained monthly.
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B5 QUALITY CONTROL AUDITS AND REQUIREMENTS
As described in Section B2, a third-party laboratory will follow their standard QA/QC
protocols for analysis of quality control samples with each set of samples analyzed. Analysis of
quality control samples may include initial calibration verifications, initial calibration blanks,
method blanks, lab control standards, matrix spikes, matrix spike duplicates, continuing
calibration verifications, and continuing calibration blanks, as required by the referenced methods.
Results of all quality control samples will be included in the verification test documentation, and
must fall within the laboratory's quality requirements. The quality of the reference measurements
will also be monitored by including performance evaluation audit samples submitted as blind (i.e.,
unknown) samples to the third-party laboratory. The performance evaluation audit samples will
be prepared from certified standards that are independent of those used for reference method
calibration, and will include prepared standards and/or matrix spikes. These samples will be used
to independently confirm that the reference measurements are being performed correctly and are
producing accurate results. The contractor's Quality Manager will perform a technical systems
audit at least once during this verification test that may include visits to both the test site and the
third-party analytical laboratory, and will audit at least 10% of the verification data obtained in
this verification test. The EPA Quality Manager will also conduct an independent technical
system audit at his/her scheduling discretion.
Steps will be taken to maintain the quality of the data collected during this verification
test. Quality control samples producing results which do not meet the laboratory's standard
requirements will be reanalyzed. If the results are still outside the required tolerance, the
reference instrument will be recalibrated and the samples will be reanalyzed. If the outlying
results persist, the affected data will be marked and the affected parts of the verification test may
be repeated. Sample results which do not meet these requirements will also be marked, and
excluded from comparison to the results obtained from other operating sites.
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B6 INSTRUMENT/EQUIPMENT TESTING, INSPECTION, AND MAINTENANCE
The equipment used for all the analyses will be tested, inspected, and maintained as per
the standard operating procedures of the third-party analytical laboratory or the standard methods
being used to make each measurement. The reference analyses listed in Section B4 require use of
the following apparatuses and instrumentation: reflux apparatus, drying oven, spectrophotometer,
stereoscopic microscope, ultraviolet unit for sanitization, autoclave or steam sterilizer, incubator,
pH meter, vortex mixer, gas chromatograph, thermal conductivity detector, continuous-flow
analysis equipment, colorimetric detector. These activities (i.e., inspection, maintenance, and test
of the instruments) will be done as directed by the third-party laboratory.
B7 INSTRUMENT CALIBRATION AND FREQUENCY
The instruments used by the third party laboratory for sample analyses (e.g.,
spectrophotometer, gas chromatograph, thermal conductivity detector, colorimetric detector,
continuous-flow analysis equipment, and pH meter) will be calibrated per the standard reference
methods being used to make each measurement or the standard operating procedures of the
reference laboratory. In the event that recalibration is necessary due to maintenance activities
performed on the analyzer or any malfunction, recalibration will be carried out by the commercial
laboratory or by the instrument vendor. All calibration records will be documented by the
commercial laboratory dedicated to the individual instruments.
B8 INSPECTION/ACCEPTANCE OF SUPPLIES AND CONSUMABLES
All materials, supplies, and consumables will be ordered by the Verification Test
Coordinator or designee. The contractor will also rely on previous experience or
recommendations from EPA advisors, stakeholders, commercial laboratory, or instrument
vendors. When possible, NIST traceable standards will be used.
B9 NON-DIRECT MEASUREMENTS
Data published previously in the scientific literature or other source will not be used
during this verification test.
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BIO DATA MANAGEMENT
Various sample analysis data will be acquired and recorded electronically or manually by
the commercial laboratory during this verification test. All maintenance activities, repairs, and
operator observations relevant to the operation of anaerobic digesters will also be documented by
the operator, contractor or host site personnel on data sheets. Results from the analytical
methods, including raw data, analyses, and final results, will be compiled by the contractor,
preferably in electronic format, and submitted to the EPA project manager at the completion of
sample analyses.
Records generated by the third-party laboratory during the verification test will be
reviewed by the contractor within two weeks of receipt before the records are used to calculate,
evaluate, or report verification results. If a contractor staff member generated the record, this
review will be performed by another contractor technical staff member involved in the
verification test, but not the staff member who originally generated the record. The review will be
documented by the person who will perform the review by adding his/her initials and date to the
hard copy of the record being reviewed. In addition, any calculations performed by the third-
party laboratory will be spot-checked by contractor technical staff to ensure that calculations are
performed correctly. Calculations to be checked include any statistical and deterministic
calculations described in the analytical methods listed in this test/QA plan. The contractor QA
staff will conduct an audit of data quality. This audit will consist of a review of at least 10% of
the test data by the contractor and/or EPA Quality Manager. During the course of any such audit,
the contractor Quality Manager will inform the technical staff of any findings and any need for
immediate corrective action. If serious data quality problems exist, the contractor Quality
Manager will request that the contractor project management issue a stop-work order. Once the
assessment report has been prepared, the Verification Test Coordinator will ensure that a response
is provided for each adverse finding or potential problem, and will implement any necessary
follow-up corrective action. The Quality Manager will ensure that follow-up corrective action has
been taken. Table 4 summarizes the data recording process.
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Table 4. Summary of Data Recording Process
Data to Be
Recorded
Dates, times,
and details of
test events
Calibration
information
Digester
parameters
Reference
method
procedures
Where Recorded
Data sheets and
testing notebook
Data sheets and
testing notebook
Recorded
electronically.
Laboratory record
books, or data
recording forms
How Often
Recorded
Start/end of test, and
at each change of a
test parameter
Prior to sample
preparation
Recorded
continuously.
Throughout sample
analysis process
By
Whom
EPA,
contractor
, and
Vendor
EPA,
contractor
, and
Vendor
EPA,
contractor
, and
Vendor
EPA,
contractor
, and
Vendor,
and
Reference
Lab
Disposition of Data
Used to
organize/check test
results; manually
incorporated in data
spreadsheets as
necessary
Manually
incorporated in data
spreadsheets as
necessary
Comma delimited
text files.
Transferred to
spreadsheets or
laboratory record
book
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SECTION C
ASSESSMENT AND OVERSIGHT
Cl ASSESSMENTS AND RESPONSE ACTIONS
Every effort will be made in this verification test to anticipate and resolve potential
problems before the quality of performance evaluations is compromised. The main objective of
these assessments is to determine whether the test/QA project plan is being implemented as
originally approved. Internal quality control measures described in this test/QA plan, which is
peer reviewed by a stakeholder group (panel of outside experts), implemented by the technical
staff and monitored by the Verification Testing Leader, will give information on data quality on a
regular basis. The Verification Testing Leader is responsible for interpreting the results of these
checks and resolving any potential problems. Technical staff has the responsibility to identify
problems that could affect data quality or the ability to use the data. Any problems which are
identified will be reported to the Verification Testing Leader, who will work to resolve any issues.
Action will be taken to control the problem, identify a solution to the problem, and minimize
losses and correct data, where possible. Independent of any EPA QA activities, the contractor
will be responsible for ensuring that the following audits are conducted as part of this verification
test.
Cl.l Performance Evaluation Audits
A Performance Evaluation audit will be conducted by the contractor's technical staff to
assess the quality of the reference method measurements made in this verification test. The
performance evaluation audit of the reference methods listed in Table 1 of Section Bl will be
performed by supplying each reference method with a blind, independent, NIST-traceable
standard provided by the contractor. The performance evaluation audit samples will be analyzed
in the same manner as for all other samples, and the analytical results for the performance
evaluation audit samples will be compared to the nominal concentration. The target criterion for
this performance evaluation audit is agreement of the analytical result within 25% of the nominal
concentration. If the performance evaluation audit results do not meet the tolerances shown, they
will be repeated. If the outlying results persist, a change in reference instruments and a repeat of
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the performance evaluation audit may be considered. This audit will be performed once prior to
the start of the test and once during the verification test, and will be the responsibility of the
Verification Testing Leader or his/her designee.
C1.2 Technical Systems Audits
The contractor or his/her designee will perform a technical systems audit once during this
verification test. The purpose of this audit is to ensure that the verification test is being performed
in accordance with this test/QA plan and any Standard Operating Procedures (SOPs) used by the
third-party laboratory. The contractor's Quality Manager, or a designee, may review the
reference analytical methods and/or SOPs used, compare actual test procedures to those specified
or referenced in this test/QA plan, and review data acquisition and handling procedures. In the
technical systems audits, the contractor's Quality Manager will tour the test site, observe
sampling and sample recovery, inspect documentation of sample chain-of-custody, and review
instrument-specific record books. He may also visit the third party laboratory where all of the
reference method analyses are conducted, to review procedures and adherence to this plan and
applicable SOPs. A technical systems audit report will be prepared, including a statement of
findings and the actions taken to address any adverse findings. The EPA Quality Manager will
receive a copy of the contractor's technical systems audit report. EPA QA staff will also conduct
an independent on-site technical systems audit during the verification test. The findings will be
communicated to technical staff at the time of the audit and documented in a technical systems
audits report.
C1.3 Data Quality Audits
The contractor Quality Manager will audit at least 10% of the verification data acquired in
the verification test. The contractor Quality Manager will trace the data from initial acquisition,
through reduction and statistical comparisons, to final reporting. All calculations performed on
the data undergoing the audit will be checked.
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C1.4 QA/QC Reporting
Each assessment and audit will be documented in accordance with Section 3.3.4 of the
ETV AMS Center QMP(2). The results of the technical systems audit will be submitted to EPA.
Assessment reports will include the following:
• Identification of any adverse findings or potential problems
• Response to adverse findings or potential problems
• Recommendations for resolving problems
• Confirmation that solutions have been implemented and are effective
• Citation of any noteworthy practices that may be of use to others.
C2 REPORTS TO MANAGEMENT
The contractor Quality Manager, during the course of any assessment or audit, will
identify to the technical staff performing experimental activities any immediate corrective action
that should be taken. If serious quality problems exist, the contractor Quality Manager is
authorized to request a stop work order from the contractor's management. Once the assessment
report has been prepared, the Verification Testing Leader will ensure that a response is provided
for each adverse finding or potential problem and will implement any necessary follow-up
corrective action. The contractor Quality Manager will ensure that follow-up corrective action has
been taken. The test/QA plan, final report, and verification statement are reviewed by EPA
quality assurance staff and the contractor management staff. Upon final review and approval, all
documents will be posted on the ETV website (www.epa.gov/etv).
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SECTION D
DATA VALIDATION AND USABILITY
Dl DATA REVIEW, VALIDATION, AND VERIFICATION REQUIREMENTS
The key data review requirements for the verification test are the collection of QC samples
as outlined in the test/QA plan, a comparison of field data sheet comments against final data to
flag any suspect data, and a review of final data to resolve any questions about apparent outliers.
The QA audits, as described within this document are designed to assure the quality of this data.
D2 VALIDATION AND VERIFICATION METHODS
Section Cl, the Assessment and Response section, provides a thorough description of the
validation safeguards employed for this verification test.
D3 RECONCILIATION WITH USER REQUIREMENTS
The data will be compiled into an ETV verification report and verification statement.
These reports will be submitted to EPA in Microsoft Word and Adobe pdf format and
subsequently posted on the ETV website.
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SECTION E
REFERENCES
1. Martin, J. H. "A Protocol for Quantifying and Reporting the Performance of Anaerobic
Digestion Systems for Livestock Manures". Interim Final September 2006; Association of
State Energy Research and Technology Transfer Institutions, U.S. EPA AgSTAR
Program, U.S. Dept. of Agricultural Rural Development.
http ://www. epa.gov/agstar/pdf/assessing_digester_perform_protocol .pdf
2. U.S. EPA. December 2002 "Environmental Technology Verification Program Quality
Management Plan", EPA/600/R 03/021.
3. Water Quality Report, 2000 available at http://www.epa.gov/305b/2000report/chp2.pdf
4. Standard Methods for the Examination of Water and Wastewater, 21th ed.; Clesceri, L. S.;
Greenberg, A. E.; Eaton, A. D., Eds.; American Public Health Association, American
Waterworks Association, Water Environmental Federation: Washington, DC, 1998; pp 5-
535-55.
5. U.S. EPA. 1983 Methods for Chemical Analysis of Water and Wastes, EPA-600/4-79-020
U.S. Environmental Protection Agency.
6. Stabel, J.R. 1977. "An Improved Method for the Cultivation of Mycobacterium
paratuberculosis from Bovine Fecal Samples and Comparison with Three Other Methods".
J. Veterinary Diagnostics Investigations, 9:375-380.
7. ASTM Methods, 2006. American Society for Testing and Materials International, West
Conshohocken, PA.
8. Martin, J. H. July 2005. "An Evaluation of a Mesophilic, Modified Plug Flow Anaerobic
Digest for Dairy Cattle Manure" For U.S. EPA Contract No. GS 10F-0036K..
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APPENDIX A
REFERENCE ANALYTICAL METHODS
A.I EPA Method 160.4 TVS
A.2 EPA Method 0410.4 COD(Colorimetric)
A.3 EPA Method 0350.1 NH3-N(Automated colorimetry)
A.4 EPA Method 0350.2 NH3-N(Titration)
A.5 Penn State Agricultural Analysis Lab: Standard Manure Test 1
A.6 EPA Method 0351.1 (Kjeldahl, Colorimetric/auto)
A.7 EPA Method 0351.2 (Kjeldahl, Colorimetric)
A.8 EPA Method 0351.3 (Kjeldahl, Colorimetric/Titrimetric)
A.9 EPA Method 0351.4 (Kjeldahl, Potentiometric)
A. 10 EPA Method 365.3 Dissolved Orthophosphate
A. 11 EPA Method 365.4 Total Phosphorus
A. 12 SM9260 D (2) Salmonella spp.
A. 13 SM2540 (2) Volatile and Fixed solids
A.14 EPA Method 150. IpH
A.15 EPA Method 160.3 Total Solids
A. 16 EPA Method 3C Biogas composition
A. 17 SM9221 A-C (2) Total coliforms
A. 18 SM5560 C (2) TVAA.19 ASTM D1954 (5) Biogas composition
A. 20 SM9230 A-B (2) Fecal Streptococcus
A.21 Penn State Ag. Lab Standard Manure Test 1
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APPENDIX B
Verification Data Sheets
General Information
1 . Name of operation
2. Address (including county)
3. Type of operation
4. Numbers and ages of livestock
5. Type of collection system
Zimmerman Farm
Pittman, PA
Mixed; waste streams from
broilers
cattle and
Notes:
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Biogas Production
1.
2.
3.
Type of digester (e.g. mixed, plug-flow,
attached film, or covered lagoon)
Name of system designer, address, and
other contact information
Digester design assumptions
a. Number and type of animals
b. For lactating cows, average body
weight or average milk production
c. Bedding type and estimated annual
quantity used
d. Manure volume, ft3/day
e. Wastewater volume, ft3/day (e.g.
none, milking center wastewater,
confinement facility wash-down, etc.)
f. Other waste volume(s), ft3/day (e.g.
none, food processing wastes, etc.)
with physical and chemical
characteristics (e.g. concentrations of
total solids, total volatile solids,
chemical oxygen demand, etc.)
4.
Physical description
a. General description including types of
construction materials (e.g. partially
below grade, concrete channel plug-
flow with flexible cover, etc.)
b. Dimensions (length and width or
diameter and height or depth)
c. Type(s), location(s), and thickness(s) of
insulation
d. Operating volume and ancillary biogas
storage volume if present
e. Design hydraulic retention time
5.
Monthly summaries of operational details
a. Number and type of animals
b. Other waste volume (s) and physical
and chemical characteristics
c. Frequency of waste addition (e.g. once
per day, twice per day, etc.)
Fully mixed with final stage attached film;
thermophilic
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Biogas Production (continued)
d. Pretreatment of digester influent (e.g.
none, solids separation by gravitational
settling, screening, etc. with details)
e. Average daily digester temperature and
monthly range
f . Treatment of digester effluent (e .g .
none, solids separation by screening,
etc. with details)
g. Method of digester effluent storage
(e.g. none, earthen pond, etc.)
h. Use of monensin or any other
antibacterial growth promoters that
could affect biogas production
Farm had been using Rumensin by Eli Lilly
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
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Version 1 January 23, 2007
Biogas Utilization
1. Biogas utilization (e.g. none, generation
of electricity, use on-site as a boiler or
furnace fuel, or sale to a third party)
a. Type of engine-generator set (e.g.
internal combustion engine, micro
turbine or fuel cell with the name of the
manufacturer, model, and power output
rating (kW) for biogas
b. Pretreatment of biogas (e.g. none,
condensate trap, dryer, hydrogen
sulfide removal, etc. with the names of
manufacturers, models, etc.)
c. Exhaust gas emission control (e.g.
none, catalytic converter, etc.)
d. If interconnected with a utility
i. Name of the utility
ii. Type of utility contract (e.g. sell
all/buy all, surplus sale, or net
metering)
e. If engine-generator set waste heat
utilization
i. Heat source (e.g. cooling system or
exhaust gas or both)
ii. Waste heat utilization (e.g. digester
heating, water heating, space
heating, etc.)
3. fuse on-site as a boiler or furnace fuel, a
description of the boiler or furnace
including manufacturer, model, and rated
capacity
4. If biogas sale to a third party, a description
of the methods of processing, transport,
and end use
ICEWaukeshaModelSl?
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
Cost Information
1.
2.
O
"As built" cost of total system
Cost basis (e.g. turnkey by a developer,
owner acted as the general contractor,
constructed with farm labor, etc.)
An itemized list component costs (e.g.
the digester, the biogas utilization
system, etc.)
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Anaerobic Digester for Energy Production and Pollution Prevention
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Page 44
Version 1 January 23, 2007
APPENDIX C
Data Checklist
Parameter
Biogas
Utilization
Factors
Operational
Information
Digester
Records
Performance
Evaluations
(PE)
Technical
System Audit
Method
Calculate Thermal Conversion
Efficiency, On-line Eff,
Average output Eff, Average
Capacity Utilization Eff.
Complete farm and facility
characterization (Appendix B)
Copy of digester operational
records kept by vendor
Inclusion of blind spiked
samples into lab samples
Facility visits, review of results
Sampling
Period
Monthly
Throughout
Study
Daily
Pre- study
and during
Throughout
Study
Sample type
Waste
Stabilization
samples
Total Data
Points/event
To be
determined
To be
determined
Method LOD
(mg/L)
Month and
study averages
During initial
phase of study
Monthly
2 events
One event
Notes
Calculated by
contractor
Completed by
contractor with
farmer and vendor
Data collected by
vendor stored
monthly by
contractor
Conducted by
Contractor QA,
results must be
within 25% of
nominal
Conducted by
Contractor QA
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
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Version 1 January 23, 2007
APPENDIX D
System Schematics
Provided by Wagner Anaerobics
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
Page 47
Version 1 January 23, 2007
Cooker Feed Tank
Blending Pit
7-3
VA-3 is Boiler
Blowoff
Automatic +7
Valve *
VA-3
J
T-WNot
Used
Manure Final
Heating Stage
Tank
D-1
WA-4
D-2
D-3
Digester
No. 3
3VA-7
I Boiler
Valves VA-4, VA-5, VA-6,
VA-7, and VA-8are110
volt solenoid steam control
valves.
B-1
Cooling heat exchanger for H2S
stripping process stream See Page
PFD-7
Feedwater Pump part of
Boiler Control Package
HE-3
D4
Digester
No. 4
nVA-8
Well Pump
Well and Well Pump not
part of contract
Boiler Feedwater Pump
Compensate Tank
Boiler Feedwater Pump
WELL
Revisions:
01/29/06-T-10NotUsed, HE-
3 Add Note
a. n
n"-
c e
II
" o
LU
d>
E
en
03 t
PFD
2
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
Page 48
Version 1 January 23, 2007
B
Alu
(,
7|MI-6
minum S
<^>
P-11
ulfate
7-5
-cxo—
Spare Pump
1
PC
^
rJM
lyelectrol
^
p-i;
yte
Digester
No. 4
Spare Chem Feed Line
r-6
Cooling heat exchanger for H2S
stripping process stream See Page
PFD-1
r
rf
D
Po
Pern
V J
tassium
anganate
AgBag East
P-17
Revisions:
01/29/06- Add information on H2S stripping System
II
O 0
° S
uu
O>
c
O) -
(TJ ^i
5 I
S
.*
C3
14
-D f J
ill
s^^,
PFD
3
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
Page 49
Version 1 January 23, 2007
TJ-
_^ :
*
t
i
h- ->•
Digester
-=No. 1
X -»
.
p [+„
i r
te Return from F
BF
-^ !
r
i
Digester
>— Wo 2
^(IWN
:Pit T ft
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-&-
P-5
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7
1
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Digester
No. 3
-^WN
1
t
j
i
I
M>1-C
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fc
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Np
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4
j*
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4
^ter
}4
4
*
4
\
X
4
»
4
4
^X^
an
H
Filtrate Return from Filtrate Pit T-8
Commissioning Return line to T-4
.
Revisions:
01/29/06 - Add foam sprinklers to Digesters 1,2,and 3,
Add digester return lines and filtrate return lines
.In
a. E
s*
«I
a E
10
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Sfl3
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TO E
Q\Si
PFD
4
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
Page 50
Version 1 January 23, 2007
Elended Marure
Surge Tank
-x-
To Digester No. 1
P-2
Revisions:
01/29/06 - Change piping for Generator Heat
Recovery, delete well water heat exchanger, add thre>
way valve for generator engine radiators
P-13
£E
a. £
ss
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
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Version 1 January 23, 2007
Revisions:
01/29/06 - Revise Gas Stripping piping and add manual valves
P-16
Condensate
Drain
ii
ii
10
O 0
° o
LJJ
0)
c
O)
(TJ
PFD
7
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
P-9
T-2
7-3
T-4
HE-2
VA-3
MI-2
HE-1
HE-8
P-2
VA-4
D
MI-7
P-12
MI-6
HE-3
B-1
Note: Manual valves and Isolating Valves
are not shown
VA-5
•a
VA-6
D-2
VA-7
L'J
D-3
VA-8
p.3 ^x p-*r^- p-s
>—"^ J—<
r-6
I
HE-5
f$ P..
7-5
Gen Set 1
HE-4
Gen Set 2
P-14
FM-15
VA-12
P-13
FM-16
tSj VA-13
D-4
VA-9
VA-11
VA-10
tft
tft
P-7a
P-7b
7-8
4—| Filter BAG J
7-7
7-9
F-17
lei
ill
£ B>«
0) •-.
U N
O
a s
ra co
LJJ
CL
re
ills
> a j\ «
PFD
8
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Anaerobic Digester for Energy Production and Pollution Prevention
Test/QA Plan
Page 53
Version 1 January 23, 2007
APPENDIX E
TEST/QA PLAN ADDENDUM
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
Environmental Technology
Verification Program
Environmental and Sustainable
Technology Evaluations
Test/QA Plan for
Verification of
Anaerobic Digester for Energy
Production and Pollution Prevention
ET/ET/ET/
TEST/QA PLAN
REVISED ADDENDUM
April 14, 2008
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
This revised addendum of the Test/QA Plan for the Verification of Anaerobic Digester for
Energy Production and Pollution Prevention was prepared by Eastern Research Group, Inc.
(ERG) under EPA contract EP-C-05-059. This addendum documents the revisions to the test
plan/QAPP document that are realized at implementing verification testing.
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
Verification Test Objectives
The following testing objectives will be implemented for the ESTE-ETV Anaerobic Digester
Verification program.
Air Quality
1. Quantify the reductions realized in methane and fossil fuel derived carbon dioxide
emissions. (The reduction in methane emissions is likely to be somewhat
minimal due to the existing method of manure storage.)
2. Assess the reduction in noxious odor emissions on subjective basis.
Water Quality
1. Quantify the reduction oxygen demanding organic compounds realized through
reduction to methane and carbon dioxide.
2. Quantify the reduction in the potential for pathogen transport to adjacent surface
waters based on reductions in indicator organism densities.
3. Characterize the transformations in nitrogen and phosphorus to assess the
reduction or increase in potential impacts.
4. Delete the dewatering/phosphorus concentration aspect of the project.
Testing Approach
1. Influent Composition. Influent composition will depend on the availability of beef cattle
manure during the 12-month period of the performance evaluation. If an adequate supply of
beef cattle manure will not be available consistently throughout the period of the
performance evaluation, the beef cattle manure that will be available will be supplemented
with broiler manure to maintain the desired volumetric loading rate. To maintain a constant
organic loading rate, the ratio, on a volumetric basis, of beef cattle manure to broiler manure
will be held constant. Only the caked broiler manure removed after each flock will be used.
2. Operating Parameters. The system will be considered ready for evaluation under steady-state
conditions when operation for a period equal to five hydraulic retention times at the influent
flow rate of 6.5 gal per minute (-33 days) with constant rates of biogas and methane
production. Methane production shall be at least 55 percent of biogas production. The
composition of the influent that will be used during the establishment of steady-state
conditions and the period of the performance evaluation shall be the same.
Temperature. The temperature of the first reactor will be held constant at 55 °C and the
temperature of the remaining three reactors will be held constant at 35 °C beginning with
the period of operation to establish steady-state conditions.
HRT. The influent flow rate will be held constant at 6.5 gal per minute, which will
provide a hydraulic retention time of approximately 6.6 days.
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
Sampling, Data Collection and Laboratory Analysis
1. Physical, Chemical, and Microbial Transformations. Monthly samples of the influent and
the effluent from the pretreatment process and of the influent to and effluent from the
anaerobic digestion system. These samples will be analyzed for the following: total solids,
total volatile solids, chemical oxygen demand, total volatile acids, total Kjeldahl nitrogen,
ammonia nitrogen, total phosphorus, total soluble phosphorus concentrations; pH; E. coli,
fecal coliform and fecal streptococcus densities; and temperature.
2. Biogas Production and Utilization. Monthly values will be determined for total biogas
production, biogas utilization to generate electricity; biogas utilization, if any, to generate
heat directly; and excess biogas disposal via flaring. Accepting the developer's statement
that flaring will not be needed for disposition of gas (emergency release only), two gas
meters (Actaris 1000A-TC meters) will be installed for measuring total biogas production
and measuring biogas production used for generating electricity for on-farm use and delivery
to the grid.
3. Electricity Production and Utilization. Monthly measurements will be completed to
determine kWh generation; parasitic demand (electric and thermal); KWh utilized on-site
and delivered to the grid.
A summary of the laboratory analytical testing requirements is provided in the following table.
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Anaerobic Digester for Energy Production and Pollution Prevention
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Version 1 January 23, 2007
Anaerobic Digester ETV - Revised Analytical Testing Requirements
Parameter
Total Solids
TVS
TVA
Fixed Solids
COD
NH3 -Nitrogen
Total Kjeldahl
Nitrogen
Total Organic
Nitrogen
Total
Phosphorus
Dissolved
Ortho
Phosphate
Method
EPA 160.3
EPA 160.4
STM(2005)
5560C (total volatile
acids)
Determined by
difference of TS and
TVS
EPA 410.4
EPA 350.1
EPA 351.2
Determined by
difference of NH3-N
andTKN
EPA 365.4
EPA 365.3
Sampling
Frequency
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Sample Type
Influent and
effluent
composites
Influent and
effluent
composites
Influent and
effluent
composites
FromAVGofTS
and TVS results
Influent and
effluent
composites
Influent, filtrate
and effluent
composites
Influent, filtrate
and effluent
composites
From AVG of
TKN and NH3
results
Influent, filtrate
and effluent
composites
Influent, filtrate
and effluent
composites
Samples
Analyzed
per Event
4
4
4
4
4
4
4
4
6
6
Total
Sampling
Events
12
12
12
12
12
12
12
12
12
12
Total
Samples
48
48
48
48
48
48
48
48
48
48
Lab
Midwest
Midwest
Midwest
Midwest
(calculated)
Midwest
Midwest
Midwest
Midwest
(calculated)
Midwest
Midwest
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Parameter
E. Coli
Total/ Fecal
Coliforms
Total/Fecal
Strep.
Salmonella
pH
NPK rations
plus total
carbon
Gas
Composition
Manure
Biodegradability
Method
STM(2002) Multiple
Tube 9223B
15 tube MPN
STM(2002) Multiple
Tube 9221A-C 15
tube MPN
STM(2002) Multiple
9230A-B 15 tube
MPN
STM(2002) Multiple
Tube 9260D MPN
EPA 150.1
Perm State Ag. Lab
Standard Manure
Testl
CH4 and CO2
ASTMD1945
Shaw Laboratory
SOP
Sampling
Frequency
Monthly
Monthly
Monthly
Monthly
Monthly
Quarterly
Quarterly
One time
Sample Type
Influent and
effluent
composites
Influent and
effluent
composites
Influent and
effluent
composites
Influent and
effluent
composites
Influent, filtrate
and effluent
composites
Solids composite
From gas flow
meter
Raw and cooked
manure and
digester influent
Samples
Analyzed
per Event
4
4
4
4
o
6
i
3
o
J
Total
Sampling
Events
12
12
12
12
12
4
4
1
Total
Samples
48
48
48
48
36
4
12
o
3
Lab
Midwest
Midwest
Midwest
Midwest
Midwest
Shaw
Midwest
Shaw
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