Decision-support for Digester-Algae IntegRation for Improved Environmental and Economic

59 Pages·2017·7.46 MB·English

INL/EXT-14-32566
Revision 0
Decision-support for
Digester-Algae
IntegRation for Improved
Environmental and
Economic Sustainability
(DAIRIEES)

User Manual

June 2017

The INL is a U.S. Department of Energy National Laboratory
operated by Battelle Energy Alliance
DISCLAIMER
This information was prepared as an account of work sponsored by an
agency of the U.S. Government. Neither the U.S. Government nor any
agency thereof, nor any of their employees, makes any warranty, expressed
or implied, or assumes any legal liability or responsibility for the accuracy,
completeness, or usefulness, of any information, apparatus, product, or
process disclosed, or represents that its use would not infringe privately
owned rights. References herein to any specific commercial product,
process, or service by trade name, trade mark, manufacturer, or otherwise,
does not necessarily constitute or imply its endorsement, recommendation,
or favoring by the U.S. Government or any agency thereof. The views and
opinions of authors expressed herein do not necessarily state or reflect
those of the U.S. Government or any agency thereof.
INL/EXT-14-32566
Revision 0
Decision-support for Digester-Algae IntegRation for
Improved Environmental and Economic Sustainability
(DAIRIEES)

User Manual
June 2017
Idaho National Laboratory
Idaho Falls, Idaho 83415

http://www.inl.gov
Prepared for the
U.S. Department of Energy
Under DOE Idaho Operations Office
Contract DE-AC07-05ID14517
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ABSTRACT
Manure management is a major concern for dairy farms, as manure emits
significant quantities of greenhouse gases and contains concentrated nutrients,
especially nitrogen and phosphorus. Current manure management practices
consist of spreading minimally processed manure on agricultural fields, which
releases greenhouse gases directly to the atmosphere and often leads to nutrient
overloading on fields and runoff to surface and groundwater. A novel manure
treatment system has been proposed that mitigates many of the current
environmental concerns and creates value-added products from the manure
including bioplastics, electricity, fertilizer, and animal bedding. The
Decision-support for Digester-Algae IntegRation for Improved Environmental
and Economic Sustainability (DAIRIEES), an Excel-based model, allows users
to enter characteristics about a dairy farm’s manure, manure management plan,
and regional market. Based on these inputs, the five main processes of the
integrated system—fermenter, anaerobic digester, bioplastics reactor, algae
cultivation, and hydrothermal liquefaction or fast-pyrolysis system—are analyzed
in detail using data from laboratory-scale experiments supplemented by
information on full-scale processes from the literature. The model can be used to
estimate performance of the integrated manure treatment system, including:
(1) carbon and nutrient sequestration, (2) quantities and market value of end
products, and (3) the system’s overall economic viability. The DAIRIEES model
outlines the major economic considerations for construction and operation of a
full-scale integrated treatment system. This information can be used to inform a
more detailed pro forma analysis of the deployed system.

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CONTENTS
ABSTRACT ................................................................................................................................................. iii
ACRONYMS ............................................................................................................................................... ix
NOMENCLATURE ..................................................................................................................................... x
1. INTEGRATED DAIRY MANURE PROCESSING SYSTEM ......................................................... 1
1.1 Overall Process Flow Diagram ................................................................................................ 1
1.1.1 Process Overview ........................................................................................................ 1
1.1.2 Process Description ..................................................................................................... 2
1.1.3 Calculations and Parameters ....................................................................................... 3
1.2 Fermenter ................................................................................................................................. 4
1.2.1 Overview ..................................................................................................................... 4
1.2.2 Process Description ..................................................................................................... 4
1.2.3. Calculations and Parameters ....................................................................................... 6
1.3 Anaerobic Digester ................................................................................................................... 7
1.3.1 Overview ..................................................................................................................... 7
1.3.2 Process Description ..................................................................................................... 7
1.3.3 Calculations and Parameters ........................................................................................ 9
1.4 PHA Reactor .......................................................................................................................... 11
1.4.1 Overview ................................................................................................................... 11
1.4.2 Process Description ................................................................................................... 12
1.4.3 Calculations and Parameters ..................................................................................... 13
1.5 Algae Cultivation .................................................................................................................... 14
1.5.1 Overview ................................................................................................................... 14
1.5.2 Process Description ................................................................................................... 15
1.5.3 Calculations and Parameters ..................................................................................... 17
1.6 Biomass Treatment ................................................................................................................ 19
1.6.1 Overview................................................................................................................... 19
1.6.2 Process Description ................................................................................................... 21
1.6.3 Calculations and Parameters ..................................................................................... 21
2. DAIRIEES MODEL ......................................................................................................................... 23
2.1 Description and Implementation ............................................................................................ 23
2.2 Model Parameters .................................................................................................................. 26
2.2.1 Herd Size ................................................................................................................... 26
2.2.2 Algal Biomass Productivities .................................................................................... 26
2.2.3 Process Efficiencies .................................................................................................. 26
2.2.4 Process Constants ...................................................................................................... 26
2.2.5 Baseline Emissions and Nutrient Release ................................................................. 27
2.3 Economic Analysis ................................................................................................................ 28
2.3.1 Operational Period .................................................................................................... 29
2.3.2 Capital Costs ............................................................................................................. 29
2.3.3 Annual Costs ............................................................................................................. 30
2.3.4 Project Financing and Economic Constants .............................................................. 30
2.3.5 Product Market Values .............................................................................................. 31
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3. GLOSSARY ..................................................................................................................................... 32
4. REFERENCES ................................................................................................................................. 33

FIGURES
Figure 1. DAIRIEES process flow diagram. ................................................................................................. 3
Figure 2. Experimental setup for fermenters at UI. ...................................................................................... 5
Figure 3. Inflow of manure slurry and outflows of liquor to PHA reactor and solids to AD. ...................... 5
Figure 4. Experimental setup of laboratory-scale AD at UI. .......................................................................... 8
Figure 5. Inflows, outflows, and products from the AD process. ................................................................... 8
Figure 6. PHA-containing microorganism (Endres and Siebert-Raths 2011). ............................................ 11
Figure 7. The chemical structure and formula for polyhydroxyalkonates (Endres and
Siebert-Raths 2011). ................................................................................................................... 11
Figure 8. Experimental setup for PHA reactors at UI. ................................................................................ 12
Figure 9. Process flow for the PHA reactors. ............................................................................................... 13
Figure 10. Process flow for algae cultivation system. ................................................................................ 14
Figure 11. Experimental setup for algae raceways. .................................................................................... 16
Figure 12. ATS deployed in Florida (Ref: http://www.algalturfscrubber.com/). ....................................... 16
Figure 13. Laboratory HTL equipment. ...................................................................................................... 19
Figure 14. Laboratory pyrolysis unit. .......................................................................................................... 19
Figure 15. Products derived from the HTL process. ................................................................................. 20
Figure 16. Products from pyrolysis. ............................................................................................................ 21
Figure 17. User input selection choices. ..................................................................................................... 24
Figure 18. Section to enter custom inputs. .................................................................................................. 25
Figure 19. Summary of economic information. .......................................................................................... 25

TABLES
Table 1. Carbon containing compounds produced by the fermenter. ........................................................... 7
Table 2. Lower heating values for methane (Ludington 2006). .................................................................. 10
Table 3. Nitrogen and phosphorous content of AD and PHA effluent (Passero et al. 2015). ..................... 18
Table 4. Ultimate analysis of solid residues after HTL at 250°C of RBB (Wei et al. 2015a). ................... 22
Table 5. Characterization of RBB biomass and biochar product (Wei et al. 2015b). ................................. 22
Table 6. Elemental compositions (wt%) of bio oils from pyrolysis of two algae strains (Miao
et al. 2004). ................................................................................................................................. 22
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Table 7. Worksheet descriptions and interactions....................................................................................... 23
Table 8. Biomass productivity rates for each algae cultivation system. ..................................................... 26
Table 9. Constants and efficiencies used in Excel model. .......................................................................... 26
Table 10. Default values used to calculate values used in the Excel model tabs of each system. .............. 27
Table 11. Formulas used to determine capital cost of each system. ........................................................... 30
Table 12. Formulas used to determine annual cost of each system. ........................................................... 30
Table 13. Project financing and economic default values........................................................................... 31
Table 14. Default values of system products. ............................................................................................. 31

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