The opportunity for commercialization of an integrated biomass to energy production unit, designed and scaled for on-farm operation, is created by the intersection of two critical drivers - the increasing need for improved, cost effective manure management systems for dairy, livestock and poultry production facilities and growing interest in alternative and renewable energy. One of the biggest challenges that livestock and dairy producers face is managing manure and process water in a way that controls odor and protects environmental quality. Economical manure management systems that are environmentally responsible and produce value-added products are needed. This process will not only help avoid energy and disposal cost, but will also create a new source of farm income, reduce nutrient emissions to the environment, and destroy pathogens and pharmaceuticals in processed manure. The proposed research will enable development of flexible process modules that can be optimized for individual farm feedstock and energy needs, allowing both economies of scale as well as customization on a farm by farm basis. Extension to livestock and poultry operations will be addressed in Phase II. It will also provide the information required for application and market development of valuable products from char. OBJECTIVES: The long term goal of the proposed effort is to commercialize a regional or farm-based slow pyrolysis unit for conversion of waste biomass to energy and other useful products. Slow pyrolysis is a thermochemical decomposition of organic material at elevated temperatures in the absence of oxygen. The feed material is dried and fed into a stirred, heated kiln. As the material passes through the kiln, a combustible synthesis gas (syngas) is evolved and is continuously removed from the kiln. Approximately 35% by weight of the dry feed material is converted to a high-carbon char material that is collected on the discharge of the kiln. Technical feasibility of the slow pyrolysis process has been demonstrated. However, further work, including market and economic assessment, is required to design and optimize a commercial system for regional or on farm use. An integrated process model optimized for the required balance of electricity for onsite use and sale, as well as production, use and sale of valuable by-products such as char, activated carbon or carbon black, needs to be developed. To accomplish this, detailed market and economic information is required. The specific aim of this Phase I SBIR project is to develop market and economic information for optimization and commercialization of a farm-based slow pyrolysis unit for farm use. APPROACH: To accomplish the goals of the project, Atodyne Technologies will conduct the following research tasks. Develop a material balance, including input/output balance, cost estimates for current operations, and waste disposal and nutrient management requirements for a model dairy farm Develop current and projected market demand estimates for potential uses for bio-char, including fuel soil amendment, or absorbent applications, as well as conversion and sale as activated carbon or carbon black. Provide product demand, specification, value and other pertinent information for use in completion of process modeling and economic optimization of onsite biomass-to-energy unit for regional and farm-based use. Develop recommendations for integrated production, use and/or sale of bio-char based by-products Develop recommendations for support resources to be developed for market development of selected products (target applications, customers, value pricing, product performance and specification requirements, packaging preferences, delivery channels and other factors required for successful marketing of targeted products)
