ENERGY RECOVERY FROM CHICKEN

MANURE INCINERATION
 Livestock industry is highly active
 3.8 milion tons of livestock waste is generated
Night Soil Animal and
Organic
Sludge, 1.9 VegitativePlant,
Sludge, 2.6
1.4

Paper and The Percentage of the Amount

Wood, 3.5 of Organic Solid Waste in
Miyazaki
(wet weight basis)
Residential
Combustible
Waste, 9.0
Livestock
Waste,
81.5
Background
Typical Livestock Manure Management and Issues

3.8 million ton/year

Composting

Livestock Manure
Much larger amount of nitrogen is applied to
farmlands compared to the standard
application ratio.

Groundwater Contamination by Nitrogen

Background
New Strategy of Livestock Manure Management
Nitrogen is emitted to
atmosphere

Energy Power
recovery Generation
Chicken Manure
Incineration Applied to farm
land as fertilizer
Incineration
ash

Pig and Cattle Manure

Composting
Environmental Conservation
Resource Conservation
Characteristics of Chicken Manure as Fuel

Decrease of Water Content in Poultry House

70% -> 40%

Low Heat Value : 1,900kcal/kg(LHV)

(Household Waste : 2,000 kcal/kg)

Manure weight is reduced to 10% of original

manure weight
Aim of The Study

 Investigation of the influence of chicken

manure incineration on nitrogen balance
 Estimation of green house gas emission
from different types of chicken manure
treatments such as composting and
methane fermentation
Outlines of Chicken Manure Incineration Facilities in
Miyazaki
Plant A Plant B

FURNACE TYPE FULIDIZED BED STOKER TYPE

CAPACITY 100,000 t/year 130,000 t/year

(300 t/day) (440 t/day)
OUTPUT OF POWER 1,960 kW 11,350 kW
GENERATION
AMOUNT OF STEAM 41 t/hour 55 t/hour
PRODUCTION (1.67MPa) (7.43MPa)
AMOUNT OF ASH 10,000 t/year 13,000 t/year
PRODUCTION
UTILIZATION METHOD FERTILIZER MATERIAL FERTILIZER MATERIAL
OF THE ASH
COST 22 million US$ 41 million US$
Chicken Manure Incineration Facility
Chicken Manure Incineration Facility
Energy Balance of Chicken Manure Incineration

Plant A
880 kw

Chicken Manure Boiler Turbine

100,000 t/year 41 t-steam/hour 1,960 kw
1080 kw

Rendring
Plant

Plant B 2,350 kw

Chicken Manure Boiler Turbine

132,000 t/year 55 t-steam/hour 11,350 kw

9,000 kw

Selling
Result of Nitrogen flow change by Chicken Manure
Incineration
40,000
Amount of nitrogen applied to the farm land

35,000 reduction of nitrogen Chemical Fertilizer

applied to farm land
in Miyazaki Prefecture (t/year)

30,000
Compost (Beef and Dairy
25,000 Cattle Manure)
20,000 Compost (Pig Manure)

15,000
Compost (Manure of Chicken
10,000 for Egg Production)
Compost (Broiler Chicken
5,000
Manure)
0
Befor the introduction After the introduction
of Broiler Chicken of Broiler Chicken
Manure Incineration Manure Incineration
Treatment Treatment

The chicken manure incineration contributes the environmental conservations.

Contents Analysis of Manure Incineration Ash

Plant A Plant B Stoker Type

(Fluidized Bed) (Stoker Type)
Sewage
C1 C2 P1 Sludge
Ash*
P 87,000 130,000 180,000 89,000
Fe 3,500 4,700 16,000 64,000
Mn 2,000 1,200 4,800 2,800
Zn 1,700 930 2,200 5,700
Cu 330 330 690 2,500
Ni 70 58 90 360
Cr 17 44 60 690
Pb 0 0 3 320
Mo 30 4 3
Cd 2 0 1 * Oshita, K., et al (2003)
Se 2 6 4 Environmental Engineering
Research, 40, pp.395-404
K 170,000 64,000 130,000 19,000
Ca 70,000 130,000 110,000 90,000
Mg 23,000 48,000 74,000 23,000 mg/kg
Na 26,000 30,000 23,000 8,600
Comparison of GHG emission from Chicken Manure
Treatment
Three scenarios are considered such as incineration, composting and anaerobic
fermentation.

Assumptions for LCA

 Emission derived from chicken manure is not
counted
 Inventory analysis is carried out using H-IWM
(Matsuto, Hokkaido Univ.)
 Plant lifetime --- 25 years
 Ash recycling and products from composting are
not included in the analytical boundary
 CH4 and N2O emissions are considered during
composting process
System Boundary for Analysis

Scenario-1 INCINERATION

Chicken Incineration Ash

Manure Transportation Facilities Sell

Energy
(Electricity)
Scenario-2 COMPOSTING

Energy (Electricity and Light Oil)

Chicken High Rate

Transportation Compost
Manure Composting
(enforced aeration)
System Boundary for Analysis

Scenario-3 METHANE FERMENTATION

Energy (Electricity and Light Oil)

Chicken Methane
Manure Transportation Fermentation Residue

Composting
Energy
(Electricity)
Compost
Sell
Some researchers are studying about chicken manure anaerobic digestion technology,
therefore we considered a methane fermentation as one of the treatment method as
a case study.
Fundamental Data for LCA

Scenario -1
Scenario -2 Scenario-3
Plant A Plant B
High Rate BIMA Anaerobic
Fluidized
Stoker Type Composting Digestion Tank with
Equipment Type Bed
Incinerator (Enforced Waste Water Treatment
Incinerator
Aeration) Plant
Amount of Chicken
Manure treated (t- 250 330 15.4 49
wet/day/facility)
The Number of
1 1 64 62
Facilities
Average
Transportation 60 40 21 21
Distance
Machine Type for
10 t Cargo-truck(70% of loadage)
Transportation
Result
(GHG Emission from Chicken Manure Treatment in Miyazaki)
200 Scenario-1 Scenario-2 Scenario-3

150
CO2 emission (kg-C/t-dry chicken

100

50 Energy Production
manure/year)

Collection
0
Operation
Incineration Composting Methane
-50 Fermentation Construction

-100

-150
NET -200 -85.8 85.1 17.8 (kg-C eq/t-dry Manure)
This result indicates that incineration of chicken manure makes a good contribution to
reduce green house gas emission.
Advanced Research
Phosphate Extraction from Chicken Manure Incineration Ash

Acid (HCl)
Alkali Agent
Manure Ash Acid Extraction Solid Residue (NaOH)

OH-
PO42- PO42-
Ca2+ PO42- PO42-
Filtration
Ca2+ Ca2+
OH- Ca2+
Ash

Added Value of Ash Precipitation

Industrial Raw Material

Heavy Metals Adsorbent 10Ca2+ + 6PO4- + 2OH-

- Waste Water Treatment
→ Ca10(PO4)6(OH)2
- Stabilizer for Fly Ash
Ongoing Research

 Pilot Plant (10kg/day  100kg/day)

 Evaluation of End Products
 Adsorbent
 Fertilizer
 Industrial Raw Materials
ex. Additives for Plastics

 Evaluation of Resource Consumption and Cost

Analysis
Conclusions

 Chicken manure incineration contributes to reduce

green house gas emission significantly
 Chicken manure incineration reduces nitrogen
applied to farmlands and it could save water
pollution by nitrogen
 Chicken manure incineration ash has great
potential for phosphate resource
Conclusions and Future Study

Feed

Industrial Raw
Material
Future study subject
- Cost Analysis
Phosphate - Energy Consumption Incineration of
Fertilizer - Cultivation Experiment Manure

Recovery of
Heavy Metals Adsorbent Phosphate
- Waste Water Treatment compound
- Stabilizer for Fly Ash
 Political map of Japan

Japan

47 Prefecture

About 3000 cities and towns

The number of incineration facility for MSW : 1,396

including 67 of gasification – melting furnaces
The number of landfill sites for MSW : 2,039
Centralization of MSW treatment

From 2005
3 incinerators were closed

SAITO-area
1 gasification melting system

- about 0.5 million peopole

- Gasification melting furnace 193*3 t/day
- about 50 t of slag and 30 t of residue from a
recycling facility will be landfilled in a day.

MIYAZAKI-area
Classification of Solid Wastes in Japan

Solid General Garbage

Wastes Wastes

Wastes
from
General General Wastes
Households Subject to Special
Wastes from
Business Control
Activiteis

Wastes
from
MSW
Sludge

Business (Municipal
Waste oil
Activities Industrial Solid Waste)
Wastes Construction Waste

Livestock Waste
:
Typical MSW Stream in Japan

Combustible Incineration
Household Waste Ash Combustible
material
MSW Landfill
Waste unsuitable for
incineration (WUI)
Non-combustible
material
Bulky Waste
Resource
Recyclable recovery
facility
Materials
Recycling
facility
Typical MSW Composition in Japan on wet basis

Bulky Waste Others

Glasses and Yard Waste
2% 8% 0%
Ceramics Food Waste
7% 28%
Metals
4%
Waste
Plasticks
9%

Plastick
Bottle
1% Waste Paper
Textile 39%
2%
Tanaka et al. (2002)
Recyclable Materials
 Outline of the studied facility:
MSW Melting facility

70t/day, 1,300 oC
Plasma Arc
Household Combustible Furnace
Molten Slag
Waste
Bottom Ash Melting
Incinerator Furnace Metal
(579 t/day,
Stoker Type) Fly Ash
Molten Fly Ash
Diagram of a Gasification / Melting Facility
Gas and Dust

Dust
MSW
Precipitator

MFA
(Molten
Slag Fly Ash)
Metals
Incombustibles
 BACKGROUND
200

Number of MSW melting facilities

180
160
140
120
100
80
60
40
20
0
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Fiscal year

The number of melting and gasification facilities in

Japan
 BACKGROUND
70000
Some parts are NOT utilized
60000

50000
ton/year

40000 Stock
30000 Disposal
Utilization
20000

10000 Slag utilization increases

0
1997 1998 1999 2000 2001 2002 2003 2004 2005

Molten slag generation in Japan

 Utilization of Molten slag in Japan (2006)

Others,
7.5 Road
Landfill constructio
cover, 12.7 n, 27.8

Filling
material, Concreate
28 aggregate,
24

Source; The Japan Society of Industrial

Machinery Manufactures, JSMIMM

However over 50% of slag is utilized as low value materials such as

filling material and cover soil in landfill or just disposed of.
Comparison of the amount of MSW between Japan and Germany
The amount of MSW generated in 2002 (million tons/ year)

60
Others
Recyclables
50
Organic waste
Bulky waste
40 Residual waste

30
The amount of generated MSW in 2004
20 Japan : 1.2 kg/person/day
Germany : 1.6 kg/person/day
10

0
Japan Germany
 Amount of MSW discharged from households

Amount of MSW [million

1200 60
Amount of MSW [g/

1000 50
/person / day]

ton / year]
800 40
600 g/person/day 30
400 20
million
200 ton/year 10
0 0
1970 1980 1990 2000 2010

Japanese environmental ministry (2004)

Trend of Treatment Methods for MSW
Directly Incineration Recycling at Recycling Plants
Recycling by Recycling Companies Directly Landfill

60

50

40
million ton

30

20

10

0
75
80
85
90
91
92
93
94
95
96
97
98
99
00
19
19
19
19
19
19
19
19
19
19
19
19
19
20
77.4% of MSW were incinerated in 2000
Recycling ratio was 14.3% in 2000 Japanese environmental ministry (2004)
Amount of Landfilling Materials and Remaining
Time of Landfill Site for MSW in Japan

Residue Directly Landfilled

Ash from Incineration Facilities and Residue from Recycling Plants
18 14
16 R em aining Tim e [year]
12
14

R em aining Tim e [year]

10
12
Milloin ton

10 8
8
6
6
4
4
2 2

0 0
1991 1992 1993 1994 1995 1996 1997 1998 1999 2000

Remeining Time of Landfill Site =

Remeining Space of Landfill Site / Amount of Landfilled Residue in a year
Target value of final disposal amount

18
16
14
million tons [

12
10 50% reduction from 2000
8
6 10% reduction
from 2000
4
2
0
1980 1990 2000 2010 2020 2030 2040 2050 2060