FINAL REPORT AVAILABILITY OF POULTRY MANURE AS A POTENTIAL BIO-FUEL FEEDSTOCK FOR ENERGY PRODUCTION By Joseph R.V. Flora, Ph.D., P.E. and Cyrus Riahi-Nezhad Department of Civil and Environmental Engineering University of South Carolina 300 Main Street, Columbia, SC 29208 Submitted to: South Carolina Energy Office 1201 Main Street, Suite 430 Columbia, SC 20201 31 August 20061SUMMARY The purpose of this project is to document the availability of poultry manure in South Carolina and assess its potential for energy generation. A GIS database obtained from the SC Department of Health and Environmental Control (SC DHEC) in April 2006 showed 805 of 808 (99.6%) currently active and proposed poultry facilities produce dry litter. It is estimated that between 400,000 and 700,000 tons of litter are produced per year. Most of the litter production comes from chicken broiler facilities, followed by turkey facilities. Kershaw county produces the most litter at over 80,000 tons/year. Eight counties produce more than 40,000 tons/year. Based on US Environmental Protection Agency (USEPA) CAFO (confined animal feeding operation) size classifications, there are 380 medium chicken broiler farms, 146 large chicken broiler farms, and 122 medium turkey farms that produce an average of 547, 1090, and 1334 tons of litter per year, respectively. A survey of 9 agricultural permits for various types of poultry farms with large litter production revealed that 5 farms apply the litter on land for farming and 4 use a manure broker. A survey of 4 manure brokers revealed that the litter collected from poultry farms is applied on farmland. The material value of poultry litter as fertilizer was calculated and compared with the material value as feedstock for energy generation via anaerobic digestion, combustion and co-firing, and gasification. This material value does not account for the cost of producing energy but included the potential value of recovered ash. Based on fifteen bulk fertilizer prices obtained for different grades of fertilizer from 5 supply companies in South Carolina, the maximum material value of poultry litter is $38/ton of chicken broiler litter and $52/ton of turkey litter. The material values of poultry litter for anaerobic digestion is $30/ton, for combustion and co-firing with ash recovery as fertilizer is $53–$57/ton, and for gasification with ash recovery as fertilizer is $46–$50/ton. Electricity production facilities estimated assuming poultry litter utilization rates of 1000 tons/year (on-site), 10,000 tons/year (off-site), and 50,000 tons/year (regional/county scale) for various technologies range from 50–70 kW, 500–700 kW, and 2.5–3.5 MW, respectively. An economic analysis accounting for capital expenditures, operation and maintenance costs, litter cleanout and transportation, and recoverable ash value reveal that gasification at a small scale (100 kW) and medium scale (1 MW) is potentially economically viable compared to anaerobic digestion and combustion. Further studies are recommended that involve a full systems analysis of a facility (e.g., poultry integrator amenable to energy production or a regional energy production facility). INTRODUCTION This project was proposed in response to solicitation number 06-IOP-06 of the South Carolina Energy Office (SCEO). The scope of work delineated in the solicitation is reiterated. The purpose of this project is to document the availability of poultry manure in South Carolina as a potential bio-fuel feedstock for energy generation. In this project, the term poultry is used to indicate chickens and turkeys farmed for economic production. Information obtained on commercial poultry facilities included current manure disposal practices and volumes of waste2created. Furthermore, several technical, environmental, economic, and policy issues were identified that would impact the development of poultry manure as a significant bio-fuel feedstock. The specific tasks identified in the scope of work are as follows: 1. Identify a minimum of five large poultry farms with significant amounts of waste availability. For each facility, document waste handling processes currently in use, quantity of waste processed, and the final disposition of the waste material. 2. Document the current disposition of waste transported for off-site processing or disposal, method of transport, and the associated commercial arrangements or issues, if applicable. 3. Document the volume of organic waste available for alternative treatment by anaerobic digestion. 4. Document the potential for on site production and use of bio-energy derived from available feedstock. 5. Document the potential for off site production and use of bio-energy derived from available feedstock. 6. Collect data relative to the total poultry farm facilities in SC sufficient to determine accurate estimates of the total quantity and quality of available poultry manure material as potential bio-fuel feedstock. 7. Estimate total organic waste available for potential anaerobic digestion processing. Present data in three separate categories (small, medium, large) of poultry farms, sized by absolute quantity of available waste with reasonable potential as bio-fuel feedstock. POULTRY FACILITIES IN SOUTH CAROLINA The South Carolina Department of Health and Environmental Control (SC DHEC) regulates agricultural facilities within the state under R.61-43 (Standards for the Permitting of Agricultural Animal Facilities) [1]. SC DHEC shows 181 permitted turkey facilities [2] and 556 permitted chicken facilities [3] in South Carolina (figures accessed in 2006). The general location of these facilities is shown in Figures 1 and 2. The term poultry in Figure 2 refers to chicken facilities. The turkey facilities are clustered in the northern mid-section of the state, while the chicken facilities are clustered in the western section of the state. To operate in the state, poultry facilities have to submit a comprehensive Animal Facility Management Plan to SC DHEC that includes the number and type of animals, the amount of animal manure and by-products generated per year, constituent concentrations in the litter, and proposed manure management/disposal/treatment approaches [1]. From a GIS database of agricultural facilities obtained from SC DHEC, 805 of 808 (99.6%) currently active and proposed poultry facilities produce dry litter, which is