Value Added Product System Provider
As an Integrated System Provider, Phase 3 Renewables will supply all the equipment, materials, and associated services for valueâ€added products derived from the byâ€products of your anaerobic digestion or gasification system.
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Animal Bedding
The process
During the anaerobic digestion process, the fibrous material in the manure is subjected to sufficiently high temperatures over an extended period of time so that nearly all pathogens are destroyed. The recalcitrant lignocellulosic materials contained in the haylage, silage, or straw bedding remain in the digestate, which now has low odor and is highly flowable. The digestate can then be mechanically processed in a screw or roller press to dewater the biofibers, typically to about 30â€35% dry matter. If desired, the fibers can be dried further using additional waste heat from the energy conversion systems. Farms can then use these fibers to replaced purchased bedding, such as sand or shavings, and realize a large cost savings. Phase 3 Renewables can provide a transition plan for dairy farms that currently bed with sand and wish to switch to biofiber bedding, to ensure herd health and cow comfort are maintained.
System requirements
Separating biofibers requires easy to operate, commercially available equipment. The equipment can run continuously throughout the day, or only during hours when operators are available to transport the biofibers to the barns.
Production potential
For dairy, beef or other bedded animals, there will typically be sufficient biofibers to replace all purchased bedding as well as sell an equal amount of excess biofibers.
Pellet Fuel or Fertilizer
The process
If biofibers are not desired for on farm bedding, as in the case of swine operations, the separated fibers can be formed into pellets. The specific process requirements for pelleting the biofibers will depend upon the make and model of pellet mill selected, but some additional drying is normally required. The size of pellet is determined by the die, and this choice will also have an impact on the throughput of the system. The biofibers can also be combined with other materials to enhance the fertilizer value of the finished pellet, such as bone or blood meal.
System requirements
Biofibers require less than 1/10th the horsepower to form pellets compared to virgin wood fibers, but finished pellets can contain equal or greater heat energy value. The pellet mill can be sized to accommodate the manner in which the farm wishes to operate the mill continuously or only several hours a day.
Production potential
Because the biofibers are both dried and compressed during pelleting, the quantity of pellets will generally be about 1/5th of both the weight and volume of the loose biofibers just after separation. A typical 1,000 cow dairy will produce about 2,070 tons per year of biofibers at 70% moisture. After pelleting, the weight will be closer to 400 - 450 tons.
Wood Plastic Composites
process
Wood plastic composites are typically made using plastic resin and fine, powdery wood dust from saw mills and furniture making. Biofibers separated from the digestate can be dried and substituted for the powder, leading to a stronger, lighter product with a slight grainy texture that looks more like real wood. The products are typically used for outdoor furniture and decking, but also increasingly in picture frames, wood trim and molding and furniture components. The biofibers can be combined with biodegradable plastics for greater environmental advantages.
System requirements and Production potential
Phase 3 Renewables is currently collaborating with universities and companies to expand the potential products, and to better define the equipment that will be required.
Aquaculture
The process
For years, the growth of algae due to runoff of nutrients into streams and ponds has been a major environmental challenge. Now however, there are exciting opportunities to use the digestate from an AD system to rapidly grow algae in specially designed systems. The algae oil can be extracted and used to make biofuels, soaps, pharmaceuticals and inks. The remaining algae biomass can be fed to animals or incorporated in the soil as a source of nitrogen. While growing the algae, excess nutrients †nitrogen, phosphorous and potassium †are removed from the digestate and a dilute irrigation water remains.
System requirements and Production potential
Phase 3 Renewables is currently collaborating with universities and companies to expand the potential products, and to better define the equipment that will be required.
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