TwoStaged Mixed Plug Flow Anaerobic Digesters

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Two-Staged Mixed Plug Flow Anaerobic Digesters

• Melissa Dvorak
• GHD, Inc.
• P.O. Box 16246 St. Louis Park, MN 55416
• [phone]
• mdvorak_at_ghdinc.net
• www.ghdinc.net

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OUR COMPANY

• Based in Chilton, WI
• Founded by Steve Dvorak, P.E. in 1989
• Packerland Digester in 1985 Still Operational
• Our First Digester
• Gordondale Farms, WI in September 2001
• Operating at 15 Sites, Nationwide
• WI, IN, VT, WA, IL, GA, MI
• Currently Building Six Digesters
• WI, IN, VT, WA

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BASIC ANAEROBIC SYSTEM FLOW DIAGRAM
WASTE STREAM
ANAEROBIC DIGESTER
5 SOILDS
BIOGAS
SOLIDS PRESS
ENGINE/ GENERATOR
LAGOON/ LIQUID STORAGE
LIQUIDS
CROP APPLICATION
35 SOLIDS
ELECTRICITY
SECONDARY TREATMENT
POWER CO. OWNER
RECAPTURED HEAT
DRYER
COMPOST
FERTILIZER (NPK)
STREAM DISCHARGE
ANIMALS
PROPERTY OF GHD, Inc.
BEDDING
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PROPERTY OF GHD, Inc.
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BIOLOGICAL SYSTEM

• Manure Collection System
• Digester Vessel
• Plug-flow Digester
• First In, First Out
• Acid Chamber
• Methanogenic Chamber
• Digester Mixing
• Biogas Recirculation
• Digester Temperature
• 101oF

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OUR SUBSTRATES

• Other Organic Wastes Added to Our System
• Bacon Bit Grease
• Restaurant/Casino/Institution Kitchen Grease
• Cheese Whey and Milk
• Distillers Grain
• Activated Sewer Sludge
• Cannery Waste (Vegetable and Fruit)
• Waste from a Ravioli Sauce Plant

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OUR SUBSTRATES

• Other Organic Wastes (cont.)
• Artificial Crab Meat and Fish Trimmings
• Potato Waste from a French Fry Plant
• Daff from a Chicken Processing Plant
• Breading and Fish Waste from a Fish Patty Plant
• Organic Refinery Waste
• Cereal Plant Waste
• Silage Spoilage

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BIOGAS CONSUMPTION

• 55 - 60 Methane (CO2 45)
• 5 to 5.5 Cows to Produce 1 kW per hour
• Gen-Set Provides Electricity and Heat
• Small Amount of H2S
• Excess Biogas Is Flared
• Considerations When Burning Biogas
• Engine Temperatures (oil coolant)
• Moisture Content of Biogas
• Pressure Requirement to Engine

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DIGESTER EFFLUENT

• Separation With Screw Press
• Liquid for Fertilizer
• 1.5 2 Solids
• Irrigation vs. Trucking
• Reduction in NPK
• pH Increase
• Solids Used for Bedding
• Roughly 70 Moisture
• Pathogen Reduction
• Clean Cows
• Somatic Cell Count/Herd Health

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AG STAR PROGRAM SAMPLING RESULTS Gordondale Farms
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PHOSPHOROUS
DOUBLE S DAIRY
GORDONDALE FARMS
LBS/ TON
12/16/2002 2/5/2003
11/01/2002

• The above data was averaged to
• -Digester Influent at 10 Solids
• -Separated Solids at 30 Solids
• Separated Liquids at 4 Solids

PROPERTY OF GHD, Inc.
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PATHOGEN REDUCTIONGordondale Farms
(x 104)
( x 106)
( x 106)
( x 106)
NOTE SAMPLES COLLECTED 2/7/03
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HERREMA DAIRY

• Located in Fair Oaks, IN
• Start-up Spring 2002
• Built for 3500 cows
• 2, 375 kW Cat engines
• Receiving 1-3
• semi-loads of substrates per week

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HERREMA DAIRY
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BOS FARM 4

• Located in Fair Oaks, IN
• Start-up Summer 2004
• Built for 3500 cows
• 2, 375 kW Waukesha engines
• Receiving 1-3
• semi-loads of substrates per week

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BOS FARM 4
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BOS FARMS 1 2

• Located in Fair Oaks, IN
• Start-up Fall 2005
• Built for 7000 cows
• No electrical generation system installed for
  herd health and manure mgmt

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BOS FARMS 1 2
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HIDDEN VIEW DAIRY

• Located in Fair Oaks, IN
• Under construction
• Built for 4000 cows
• Intend to produce electricity

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HIDDEN VIEW DAIRY