ENVIRONMENTALLY SUPERIOR

TECHNOLOGY

ORBIT/HSAD

“On-campus Report”

Prepared by: Dr. Leonard S. Bull, PI Dr. Maurice Cook, CO-PI Sample collection and custody supervised and coordinated by: Ms. Lynn Worley-Davis ORBIT Technology Providers: Mr. M. Allen Paul and Mr. James Tarleton ORBIT 484 Hickory Grove Road Clinton, NC 28328 Tel: 910-564-3248 orbit@intrstar.net PI Contact: Dr. Leonard S. Bull, PAS Box 7608 NCState University Raleigh, NC 27695-7608 919-515-5387 leonard_bull@ncsu.edu Prepared May, 2004

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TABLE OF CONTENTS

Item Page 1. Executive Summary……………..………………………………………….3 2. ORBIT High Solids Anaerobic Digestion (HSAD)Technology….…..…..4 3. Figure 1-Flow Process for HSAD Treatment of Swine Waste……….….4 4. Figure 2- Spatial Arrangement of Facility at Site………….…………….5 5. Performance Parameters Covered in this Report………………………..6 6. Tables of Primary Data and Calculations……………………….………..8 7. Table 1- Processing/Recovery of Swine Waste Solids/Nutrients by

ORBIT/HSAD……………………………………………………………..8-9 8. Table 2. Composition of Digestion Input and Output Used in Table 1

Computations……………………………………………………………....9 9. Weight Differences………………………….…………………………….10 10. Solids Decomposition and Methane Production………………….……..10 11. Accountability for Nitrogen……………………….…….………………..10 12. Accountability for Ammonia………………….……….….……………...11 13. Accountability for Phosphorus…………………………….…………….11 14. Accountability for Copper…………………………………….………….12 15. Accountability for Zinc…………………………………………….……..12 16. Operating Considerations………………………………………....……...12 17. Discussion……………………………………………………………...…..13 18. Appendices……………………………………………………………..15-30

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Executive Summary

The objective of this study was to evaluate the effectiveness of the innovative high solids anaerobic digestion (HSAD) technology in treating swine waste. This technology is distinctive from other anaerobic processes in that relatively high solid concentrations, viz., greater than 30 percent, can be digested. The digestion is accomplished by thermophilic anaerobic bacteria. The evaluation was made at the ORBIT facility in Sampson County, NC. Swine waste was provided by the SuperSoil Systems (SSS) facility at Goshen Farm in Duplin County, NC. The following analyses were conducted on the swine waste prior to and following anaerobic digestion during a 70-day test period: 1) Solids percentage; 2) Total nitrogen (N); 3) Ammonia (NH3); 4) Phosphorus (P); 5) Copper (Cu); and 6) Zinc (Zn). Biogas production was measured by the technology provider. Pathogens were identified and assessed by the OPEN team. The solids content of the original swine waste feedstock was approximately 15%, about one-half of the content required to meet the high solids criterion of at least 30%. The solids content of the processed feedstock was approximately 11%. However, the total quantity of solids before and after processing was about the same.

Total N diminished by approximately 50% during processing. Ammonia decreased by about 72%. Reductions in P, Cu, and Zn were 26%, 46%, and 32%, respectively. The technology provider reported the production of large amounts, up to 81,500 liters per day, of methane. The OPEN team reported the destruction of almost all the harmful pathogens. These results indicate that this system quantitatively eliminates unaccounted-for discharges of critical elements and compounds into the environment.

Several factors limited the evaluation of the technology: 1) Inadequate quantities of swine waste to utilize the full capacity of the system; 2) Variable composition of the swine waste feedstock; 3) Brevity of the evaluation period, 70 days. Despite these limitations, the evaluation indicates that the HSAD system is a promising innovative technology.

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ORBIT High Solids Anaerobic Digestion (HSAD) Technology General Description

This innovative technology utilizes thermophilic anaerobic digestion and bacteria adapted to these conditions (54.40C as goal) to digest the solids in swine waste, recover energy in the form of biogas, and eliminate pathogenic organisms. This system is distinctive from most other anaerobic processes in that relatively high solid concentrations, e.g., >30% (35-40% preferred), can be digested. The effectiveness of HSAD is based on the theory of film transfer of digestive products between anaerobic microbes in a high-solids environment. The synergistic interaction of thermophilic organisms and high solid concentrations should reduce the construction and operating costs of the HSAD system when compared to conventional mesophilic (340C) systems. A schematic diagram of the HSAD flow process for treatment of swine waste is shown in Figure 1. A logistical layout of the facility as actually constructed in Sampson County, NC is depicted in Figure 2.

Flow Process and Data Collection Points

Notes:1. Biogas was flared throughout the test. BudgetDid not allocate funds for testing gas collection, storageand Co-Gen components because they are off-the-shelf Items that are widely used already.2. Digested Sludge Was Deposited in Barrelsor Transferred to SSS3. Digested sludge in barrels is non-hazardous and willkeep indefinitely. 4. Dotted lines and boxes indicate potential usage of products.

Circled Numbers Identify Specific Data Collection Locations

1 2 3 4

Swine Waste Separation

at Goshen Farm

Transport of Waste from Goshen FarmTo ORBIT Facility

Receipt ofSwine Waste

Transfer to FeedMixing Tank

5

Anaerobic BioreactorDSR-2

Digested Sludge

Gas Flare

Transferred DirectlyTo SSS

Stored in Barrels

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Collection of feedstock samples; On-site lab tests on pH and moisture.

Co-Gen or Direct Feed to Boiler Type

Furnaces

Conversion to Fertilizer for Ground Application

Figure 1. Flow Process for HSAD Treatment of Swine Waste

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Methane - flared

Swine solids were loaded into the blender and then carried via belt to the feed tank of DSR2. Digested solids did not go through the screw press for additional separation during this evaluation of the HSAD. All methane was flared.

Liquid storage

Composted solids

Screw press for liquid removal

Port 4

Port 2

Port 1

HSAD DSR1

HSAD DSR2

Feeder – Homogenization (Blender)

Grinder

Blender

Port 3

Figure 2. Spatial Arrangement of ORBIT Site, Showing Two HSAD Units, Feedstock Flow and Location of Sampling Ports in Test Digestion System (HSAD DSR2), Liquid/Solid Separation Unit (not used) with Flow of Separated Solids and Liquid, and Biogas (Methane) Collection/Flaring Unit

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Swine waste was collected at the SuperSoil Systems (SSS) facility at Goshen Farm in Duplin County, NC. (By contract, this was the sole source of material to be used in the evaluation. Prior to this evaluation, food preparation and dining hall waste was processed in the digestion units as part of a contract with the US Army and was used as the initial charge of feedstock to the DSR2 unit.) The swine waste received from SSS had been treated with chemical additions to remove nutrients. The description of that process can be found in the report on the SSS system. Swine waste was transported to the ORBIT facility in Sampson County and emptied into a large rotary ribbon blender for mixing. ORBIT personnel (hereafter referred to as “technology provider”) weighed the feedstock daily and checked it for moisture content, pH and toxicity. The feedstock was then fed via screw conveyors to a 4-ton capacity surge bin, where precise rates for application of it to the digester were determined. The feedstock was transferred to the digester via a pneumatically retractable and heated screw conveyor, with target temperature of the feedstock to be 54.40C at the time of introduction into the digester. This process required from two to five hours, at which time the digester was sealed until the next feeding period (approximately 24 hours). The digester was heated to 54.40C by means of thermostatically controlled heaters in integral contact with the vessel walls. The contents were gently stirred to release the continual development of biogas, which was removed from the digester, measured (volume) and disposed of by flaring. The preferred commercial fate for the biogas is as an energy source with value recovered to help support the operation of the system. Daily digestate samples were collected from four ports evenly spaced along the length of the digester. The schematic diagram indicates that there is provision for separation of the liquid and solid fractions of the digestate exiting the unit for subsequent value-added product development, e.g., liquid fertilizer, compost. That step was not employed in this testing program due to financial constraints. In addition, the biogas produced during this test was flared rather than being used as a recoverable energy source. In a full-scale production application of HSAD, it is expected that liquid and solid products would be produced and that the collected biogas would be used as an energy source to provide revenue streams. Without data, however, this report cannot address those components.

Performance Parameters Covered in this Report The focus of this report is to describe the fate (destruction or recovery with containment) of the following materials and nutrients associated with the feedstock entering the digester and digestate exiting the digester: a.) solids; b.) total nitrogen; c.) feedstock and digestate ammonia (NH3); d.) phosphorus; e.) copper; f.) zinc. All of these components were measured according to the requirements of the Agreements, indicating that a third party collected, secured, transported and analyzed the samples. Numerous other data were gathered during the project by the technology provider. Some of those, especially the methane production that is central to anaerobic digestion, are included among the Appendices to this report. They are designated in each case as being “Collected by the Technology Provider” in each case for clarity. This report emphasizes

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the specific components noted above and it also includes a discussion of system operational requirements, considerations and recommendations.

The design and purpose of the total containment ORBIT/HSAD system, as noted above, is to process high-solids (35-40 % solids) biomass at thermophilic anaerobic conditions (54.40C) with extraction of recoverable and usable energy as methane, elimination of odor producing compounds, expected elimination of pathogens by virtue of the temperature used, and recovery and control of nitrogen forms and mineral elements (especially phosphorus, copper and zinc). A documented advantage of the thermophilic digestion process is the elevated rate of reaction and therefore theoretically reduced process (retention) time. By virtue of the total containment and quantitative collection of exiting material, protection of groundwater and the surrounding environment is assured. Theoretically, any non-volatile element added to a single-vessel component system should be quantitatively recovered and, thus, can serve as the basis for calculation of mass-balance. Because of the sealed nature of the system and the fact that it was sited at a location which had no animal production, the only emissions that would be expected (ammonia, odors) would be those associated with the handling of the feedstock prior to introduction into the system, and the subsequent handling of the digestate exiting from the system. The extent of those possible events (emissions) would be dictated by the nature of the material and the operational procedures employed by the technology provider. Prior to swine solids being introduced, material from testing done previously using food residue material was put into the unit to “seed” the thermophilic anaerobic digestion process. Swine waste feedstock was introduced into the unit from August 19-29, from October 24-November 4, and from November 6-29, 2003 (Appendix Table 4). Due to the interrupted feeding schedule and variable quantities of feedstock introduced as a result of variable availability, “steady state operation” was never achieved during this test. The expected retention time of material in the digestion unit was anticipated to be from 7-21 days, depending on loading rate. Due to the variable and interrupted loading rate, it is not possible to calculate an average retention time. Consequently, data are presented in this report based on three different estimated retention times. The fact that the feeding rate was never more than about 20 percent of the capacity of 5,400kg/day (technology provider estimate) would suggest that the retention time was longer than would be observed under full-operating, steady-state conditions. Also, nutrient recovery evaluation would require collection of digestate for an extended time after cessation of feeding of the material. The total period for collecting data was September 11 through November 29, 2003. This period coincided with the availability of swine waste feedstock and the monitoring of ammonia emissions, odors and pathogens by the OPEN team. The test ended ahead of schedule due to operational and financial difficulties. That made this evaluation more difficult to conduct than originally intended. As noted earlier, the digestate was not processed to separate liquid and solid fractions. Thus, there are no data on the distribution of nutrients between those components. The digestate was collected in 55-gallon barrels, which were sealed and stored for future use. All biogas produced was flared.

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Tables of Primary Data and Calculations All of the critical data required for this evaluation are summarized in Tables 1 and 2 below. The sampling schedule and a complete dataset for all of the analyses are found in Appendix Tables 1 and 2. These data are based on the quantities introduced into and removed from the digestion unit, and the analysis of samples taken by the On-Campus team, with all subsequent chemical analyses conducted by the Division of Agronomic Services of the North Carolina Department of Agriculture and Consumer Services.

During the test period, eight samples of the material being introduced into the digestion unit were taken and analyzed. Because the performance is based on the difference between what is introduced and what is recovered from the material introduced, and to assure that previously processed food-waste material was totally cleared, only five samples of the material exiting the digestion unit were analyzed. This is based on the originally estimated retention time of 21 days provided by the technology provider (not actually measured-see below). All material introduced into the digestion unit was weighed daily by the technology provider, and all material collected from the digestion unit was weighed by On-Campus team members. The digestion unit is equipped with four sampling ports as described above and shown in Figure 2. Ports 1-3 were used as indicators of internal change in composition during processing. Port 4 was at the point of discharge from the unit. The results of all of those analyses are found in Appendix Table 2.The port 4 sample analyses were used as indicative of the composition of the discharge material resulting from the processing of swine waste by the unit, although a review of the data from ports 1-3 suggest that the majority of digestive activity was completed in the first portion of the digestion unit. The results shown in Table 1 are calculated based on 7, 14 and 21 day estimated retention times due to the variable feedstock addition schedule and the relatively low feeding rate (related to capacity). The difference between each of these calculations is the fact that digestate weight was included from those periods (7, 14, 21 days) after the last feeding to accommodate those three retention time estimates. Table 1. Processing / Recovery Of Swine Waste Solids / Nutrients By ORBIT /

HSAD Parameter Quantity In Quantity Out Loss/(Gain) Loss/(Gain)_Recovery_ -- kg kg kg % %

7-day Estimated Retention Time Total Weight 30,706 30,976 (270) (0.9) 100.9 Solids 4,636 3,314 1,321 29 72 Total Nitrogen 1,424 621 803 56 44 Ammonia 87 25 62 71 29 Phosphorus 683 507 176 26 74 Copper 69 37 32 46 54 Zinc 45 31 14 31 69

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Table 1. Processing / Recovery Of Swine Waste Solids / Nutrients By ORBIT / HSAD (continued)

Parameter Quantity In Quantity Out Loss/(Gain) Loss/(Gain)_Recovery_ -- kg kg kg % %

14-day Estimated Retention Time

Total Weight 30,706 34,347 (3,641) (84) 108 Solids 4,636 3,675 961 21 79 Total Nitrogen 1,424 689 735 51 49 Ammonia 87 28 59 68 32 Phosphorus 683 562 121 18 82 Copper 69 42 27 39 61 Zinc 45 34 11 24 76

21-day Estimated Retention Time Total Weight 30,706 40,054 (9,348) (30) 130 Solids 4,636 4,285 350 8 92 Total Nitrogen 1,424 804 620 44 56 Ammonia 87 32 55 63 37 Phosphorus 683 656 27 4 96 Copper 69 49 20 29 71 Zinc 45 40 5 11_____ 89______ Notes on Table 1 data:

a. Analytical data are found in Table 2. Complete analyses are found in Appendix Table 2.

b. Values in ( ) represent gain in weight. Table 2. Composition Of Digestion Input And Output Used In Table 1

Computations Sample_Source___n___Solids_____TotalN_____NH3_____P_______Cu______Zn__ -- -- % ppm ppm ppm ppm ppm Input Material 8 15.1 40637 2841 22242 2252 1472 Std. Dev. 3.1 14873 2636 6803 955 527 Output Material 5 10.7 20063 808 16379 1212 996 ______Std. Dev. .64 4837 1039 4504 549 267 Notes on Table 2 data:

a. Nutrients in Parts Per Million (ppm) as-received basis (1 ppm = 1 mg/1000g).

b. Input material at 15.1 percent solids from supplier was at less than 50% of system performance design and recommended specifications (35-40%).

c. Output material is collected from port 4 of the digestion unit. All data for all samples shown in Appendix Table 2.

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Weight Differences

The fact that the weight of material added to the digestion unit was less than that removed for each of the Estimated Retention Times is baffling. A partial explanation may be that there was a lower solids content in the removed material than that added. With extension of the digestate collection period to accommodate the longer Estimated Retention Times, the weight difference increased. Since weight is not a critical parameter per se, and since there are concerns about the irregular feeding patterns and unknown retention times, no further discussion of the wet weight data will be made.

Solids Decomposition and Methane Production

The primary interest in solids disappearance is related to the production of biogas (methane and carbon dioxide) as a method for extraction of useful energy from the system in a form that has added value. Data collected by the technology provider (see Appendix Table 3) indicated that the swine waste solids contained 79% of volatile solids (VS), and that the conversion of those VS to biogas was predicted to be 51% based on theoretical calculations. This should have resulted in a reduction in solids passing through the digestion unit of about 40%. That reduction was not achieved under any of the Estimated Retention Times. The data on estimated and measured methane production (Appendix Figure 1, provided by technology provider) show variable production rates during the time of actual measurement (10/31-11/27/03). The range in daily methane yield is from 0-81,500l/day. In some cases the yields reported were above theoretical estimates, and in other cases they were below. We believe that the variable flow created by the feeding pattern noted above is responsible for these variations.

Accountability for Nitrogen

Ability to account for, contain and manage nitrogen within a waste processing system is an important performance parameter. In a component and sealed system such as ORBIT/HSAD, the tracking of nutrients should be relatively easier than in more complex, multi-component systems with numerous transfers and partitioning functions.

The nitrogen analysis data from the samples taken of input and output material are found in Table 2 above. Total nitrogen balance (all forms) across the digestion system during the 70-day test interval is shown in Table 1. Only 44-56% of the nitrogen introduced into the system can be accounted for. The specific percentage depends on the Estimated Retention Time used. That recovery is disappointing. We attribute these differences to a combination of uncertainties associated with the weights obtained, the small number of digestate samples (5) that were collected and analyzed, the lack of steady-state operation, and uncertain retention time. These erratic findings point to the need for steady-state operation with an extended sampling period in future evaluations. The unaccounted-for nitrogen, other than that due to analytical and sampling causes, could be partly due to a small amount exiting with the produced biogas. This is not considered a major loss avenue due to the pH of the digestion mixture (7.5-8.3).

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Accountability for Ammonia

The concentrations of ammonia in the input and output samples are shown in Table 2 above. There is a concentration decrease of nearly 75% between input and output. The balance of ammonia calculated from those data indicates that from 63-71% was lost during the process, depending on the Estimated Retention Time used. The same uncertainties can be assigned to these data as are noted above, including the possibility that some ammonia was lost in the biogas stream. The report of the OPEN team evaluations of this site (see OPEN team report) suggests that ammonia emission at this site was not high. Ammonia was detectable around the digestion site, and that may have been due to the combination of some emissions from the feedstock, the digestate, and the fact that there was an operating composting facility on the same site located “upwind” from the ORBIT facility.

Accountability for Phosphorus

The recovery data for phosphorus are shown in Table 1. Concentrations of total phosphorus in samples of input and output materials to the digestion unit are found in Table 2. The balance of phosphorus calculated from those data and the weights of materials resulted in our being unable to account for from 3.9-26% of the input phosphorus, for the three Estimated Retention Times. In a closed system such as this, the expected theoretical recovery is 100% for a non-volatile mineral such as phosphorus under extended steady-state conditions. It is anticipated that a full recovery of phosphorus would occur if tests were conducted under steady-state conditions created by a more nearly constant feeding protocol. A common practice in many analytical procedures is the use of a non-volatile element as an internal marker that allows adjustment of all data to an assumed 100 percent recovery of that marker. That probably would have been useful in this evaluation. While phosphorus may not be the element of choice, an extensive and statistically-based evaluation of all of the non-volatile mineral elements included in the analyses conducted as part of this project could yield candidates for consideration in future testing. A review of the data in Table 1 suggests that the true retention time for the system under the conditions employed would be slightly longer than 21 days to achieve 100% recovery of phosphorus. The same projections could be made using other non-volatile elements.

Accountability for Copper

The balance of copper through the system is shown in Table 1. As a point of interest, the animals from which the waste was collected prior to pre-processing (Super Soil, USA) in this study were managed to the exclusion of sub-therapeutic use of antibiotics in production, but with elevated levels of dietary copper as an alternative. For that reason, copper concentration in the material processed here was notably high (Table 2). Based on those data, the unaccountability for copper during the test period ranged from 29-46% of that put into the system, for the three Estimated Retention Times. One

11

could use the same approach here as for phosphorus, and estimate that under the conditions used, exiting digestate collection would have needed to be measured and sampled for longer than the 21-day period used at the end of the test period to achieve full copper recovery.

Accountability for Zinc

The balance of zinc through the system is shown in Table 1.Zinc concentrations in material put into and collected from the digestion unit are shown in Table 2. Based on those data, the unaccountability of zinc during the test period ranged from 11-31% of the amount introduced. As with the results for phosphorus and copper balances noted above, a quantitative recovery of zinc should be expected during steady-state operation for an extended time, and these data suggest that to be the case, with a retention time that is longer than that used in this test.

Operating Considerations

The ORBIT/HSAD system is designed to operate with a feedstock solids content of 35-40 percent for optimal biogas production and value-added product output. The solids content of the feedstock used in this study averaged 15.1 percent during the 70-day evaluation period. Thus, optimal performance of the high solids feature of the system was probably not realized. It is difficult to ascertain from this brief study if a high solids content of feedstock is essential for the system to qualify as an effective new technology option. Obviously, the description of the high solids aspect of the system would need to be modified in the event that the solids content of the feedstock does not reach the levels for which the system was designed.

It is notable that the OPEN team evaluation (to be found elsewhere) indicated that

the HSAD system performed extremely well in pathogen destruction.

The system requires an adequate and consistent supply of feedstock to attain maximum efficiency. In addition to the low solids content noted above, the swine waste solids provided for the operation of the system were deficient in quantity and variable in composition. The potential capacity of the system is approximately 6,000 kg per day. The average feeding rate during the 70-day trial was 270 kg per day. Large variations in the amounts of nitrogen, ammonia, phosphorus, copper, and zinc in the feedstock were noted earlier in this report. These deficiencies limited the function of the system and, hence, any evaluation of the system.

Large amounts of solid digestate were produced by the digestion process. A utilization plan for these solids needs to be developed. A conceivable use is as a soil amendment. Storage of the byproducts in 55-gallon barrels, the current practice, is an inadequate long-term solution.

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Large amounts of biogas high in methane were produced by the operation. The disposition and/or utilization of this gas need to be addressed. The disposal of the methane-rich material by flaring may pose an environmental concern. The large amounts of methane (up to 80,000 liters/day) can be viewed positively as a source of energy when properly utilized.

The system requires at least one skilled operator. Additional personnel are likely required if the system is adopted as a regional collection facility. The operator must have a high school education as a minimum. The operator needs to receive adequate training that includes detailed information on equipment, its operation and maintenance, identification and reporting of malfunctions, and troubleshooting. The training should also include health and safety requirements, and record keeping.

Attention needs to be given to biosecurity. It appears that there are no compliance measures for personnel entering and leaving the property.

Discussion The ORBIT/HSAD system represents a single vessel component for waste management, unlike the more comprehensive and multi-component or multi-compartmental systems. For that reason, the entire performance evaluation is based on a single set of input and output samples taken across the digestion unit. The transit time of material through the digestion system was projected by the technology provider to be between 7-21 days. It is based on continual feedstock introduction and modest mixing of the feedstock during that transit. These processing actions should cause the samples of effluent to reflect the composition of influent 7-21 days earlier plus the influence of internal mixing during transit. If the system operated with a constant feeding rate (which was not possible due to erratic feedstock supply and periods of interrupted feeding), and if the composition of the feedstock was relatively constant, a mass balance could be calculated that would represent the true operational capability of the system. Steady state operation is a definite requirement for any system of this type in order to achieve reliable estimates of mass balance of any of the critical nutrients associated with this performance verification program. Since that condition was not achieved, as discussed in this report, these data are limited in their interpretation within the context of the conditions of this test period. These data suggest strongly that in order for a truly functionally and economically representative test of the ORBIT/HSAD system to take place the following would have been needed:

a. Feedstock availability daily at a quantity consistent with the capacity of the system (not achieved in this test and a serious disadvantage);

b. Feedstock composition of either low variability or accompanied by daily aliquot sampling for analysis (not achieved in this test);

c. Daily representative sampling of effluent discharged from the digestion unit for analysis (not achieved in this test).

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Prior to the initiation of the swine waste solids tests upon which this report is based, a very successful test was conducted by ORBIT/HSAD using food waste under contract with the U. S. Army (Fort Bragg, NC). That test was reviewed and certified by the U. S. Army, and there are significant data contained therein that demonstrate the effectiveness of the HSAD process when operated at an appropriate feeding rate. The Executive Summary of that report is found in the Appendix of this report.

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APPENDICES

15

Appendix Table 1. Sample Collection Schedule for HSAD System During Test Period _______________________________________________________________________ Date Feed tank Port 1 Port 2 Port 3 Port 4__ 8/20/03 X N/A N/A N/A N/A 8/27/03 X X N/A N/A N/A 9/3/03 X X X N/A N/A 9/17/03 X X X X N/A 9/22/03 X X X X X 9/29/03 X X X X X 10/13/03 -- X X X X 10/20/03 X X X X X 11/12/03 X X X X X____ Notes: a. N/A indicates dates when no sample were taken based on expected

transit time for material through digestion unit. b. No sample was available on 10/13/03

16

App

endi

x T

able

2. A

naly

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f Fee

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ampl

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Sam

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est P

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(all

in p

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)

Dat

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(tot

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IN-N

NH

4N

O3

OR

-NU

rea

PZn

Cu

%D

M

*8/2

0/20

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stoc

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142

656

649

7.45

5048

61.

8615

301

1159

1639

21.2

98/

27/2

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feed

stoc

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137

701

1125

709

416

3587

622

.117

610

1485

2605

17.4

69/

3/20

03

feed

stoc

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153

233

6897

6772

125

4633

723

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288

1958

3157

11.9

9/17

/200

3 fe

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1779

296

592

540

1682

712

.614

885

761

973

12.8

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feed

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145

459

3725

3431

320

4270

835

922

518

1803

2902

13.9

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29/2

003

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117

958

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35.2

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1791

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5518

326

959

994

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910

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2003

fe

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n/a

n/a

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n/a

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n/a

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feed

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kO

150

482

6118

6021

9744

364

20.9

3140

522

9234

4715

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11/1

2/20

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feed

stoc

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151

330

4309

4191

118

4702

139

2660

213

5922

9915

.29

Mea

n 40

637.

1329

80.0

428

41.6

514

1.69

3769

1.50

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241.

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52.0

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Std

dev

1487

2.70

2646

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2635

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228.

6712

1.46

6803

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520.

6895

5.48

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8/27

/200

3P

ort 1

O2

1423

514

1710

1640

112

818

11.3

8257

422

448

9.79

9/3/

2003

P

ort1

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1417

390

781

690

.113

267

7.27

1276

153

857

711

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17/2

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Por

t1O

212

594

319

298

2112

275

5.12

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656

362

212

.28

9/22

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3 P

ort1

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2028

310

0675

625

019

277

152

1135

674

985

611

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3 P

ort1

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1589

735

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3315

861

0.73

1466

575

278

210

.86

10/1

3/20

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Por

t1O

215

262

57.3

44.7

12.5

1520

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9814

301

987

927

9.87

10/2

0/20

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Por

t1O

228

714

2964

2735

229

2575

012

.320

634

1293

1829

12.3

111

/12/

2003

P

ort1

O2

1909

915

2597

155

417

574

19.6

1685

783

612

3111

.41

Mea

n 17

532.

1310

28.8

683

2.88

195.

8716

503.

3826

.16

1391

5.88

767.

5090

9.00

11.2

4St

d de

v 52

01.9

797

0.37

864.

7720

1.62

4446

.07

51.2

337

11.3

427

8.64

443.

120.

99

17

Dat

e

Sam

ple

Cod

eN

(tot

al)

IN-N

NH

4N

O3

OR

-NU

rea

PZn

Cu

%D

M

9/

3/20

03

Por

t 2

O3

1115

7 60

9 54

2 67

10

549

7.8

1230

0 52

3 52

8 12

.02

9/17

/200

3 P

ort2

O3

1265

537

032

941

.412

275

010

182

473

540

10.5

79/

22/2

003

Por

t2O

316

842

820

580

239

1602

322

.710

609

656

725

11.3

9/29

/200

3 P

ort2

O3

1686

040

.431

.68.

8516

819

0.78

1685

391

482

910

.87

10/1

3/20

03

Por

t2O

315

660

45.5

3411

.515

615

0.65

1369

489

081

910

.82

10/2

0/20

03

Por

t2O

328

208

2812

2710

102

2539

613

.721

791

1319

2062

13.0

911

/12/

2003

P

ort2

O3

1570

581

873

087

.614

888

24.1

1654

283

312

3410

.76

Mea

n 16

726.

7178

7.84

708.

0979

.62

1593

7.86

9.96

1456

7.29

801.

1496

2.43

11.3

5St

d de

v 55

02.0

295

0.04

922.

6678

.78

4724

.10

10.4

241

25.2

928

7.50

539.

250.

91

9/17

/200

3 P

ort3

O4

1329

542

534

381

.412

870

5.65

1169

350

954

911

.64

9/22

/200

3 P

ort3

O4

1930

190

362

228

118

398

11.8

9869

692

781

11.4

19/

29/2

003

Por

t 3O

427

603

55.1

46.1

927

547

0.81

2236

413

8415

0710

.27

10/1

3/20

03P

ort 3

O4

1909

746

.535

.511

1905

10.

8713

631

979

918

8.7

10/2

0/20

03

Por

t3O

429

021

3583

3475

109

2543

827

2367

213

6220

9712

.55

11/1

2/20

03

Por

t3O

417

218

942

874

67.3

1627

625

.318

339

901

1335

11.5

5M

ean

2092

2.50

992.

4389

9.27

93.1

219

930.

0011

.91

1659

4.67

971.

1711

97.8

311

.02

Std

dev

6133

.17

1327

.93

1303

.48

100.

1755

61.8

711

.76

5735

.17

352.

0556

4.97

1.35

9/22

/200

3 P

ort4

O5

1762

679

156

922

216

835

8.81

1111

673

582

810

.95

9/29

/200

3 P

ort4

O5

1806

149

.434

.714

.618

012

0.55

1695

095

891

210

.63

10/1

3/20

03

Por

t4O

517

651

45.2

33.7

11.6

1760

60.

713

518

933

839

10.6

610

/20/

2003

P

ort4

O5

2870

226

8025

5712

326

022

15.5

2301

914

4821

0811

.24

11/1

2/20

03

Por

t4O

518

273

949

846

103

1732

423

.717

295

908

1376

9.56

Mea

n 20

062.

6090

2.92

808.

0894

.84

1915

9.80

9.85

1637

9.60

996.

4012

12.6

010

.61

Std

dev

4837

.38

1076

.67

1038

.64

87.1

738

59.9

39.

9445

03.8

626

7.20

549.

160.

64

18

App

endi

x T

able

3.

Tec

hnol

ogy

Prov

ider

’s D

aily

Ope

ratio

n L

og -

Bio

gas P

rodu

ctio

n D

ata

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yFr

iday

01-A

ug-0

329

Sat

urda

y

02-A

ug-0

334

Sun

day

03

-Aug

-03

37

Mon

day

04

-Aug

-03

38

Tues

day

05

-Aug

-03

38

Wed

nesd

ay

06

-Aug

-03

39

Thur

sday

07-A

ug-0

339

Frid

ay

08-A

ug-0

3 G

ot h

eat g

oing

to D

SR

2.

29

Sat

urda

y

09-A

ug-0

339

Sun

day

10

-Aug

-03

43

Mon

day

11

-Aug

-03

29

Tues

day

12

-Aug

-03

39

Wed

nesd

ay

13

-Aug

-03

44

Thur

sday

14-A

ug-0

339

Frid

ay

15

-Aug

-03

43

Sat

urda

y

16-A

ug-0

346

Sun

day

17

-Aug

-03

48

Mon

day

18

-Aug

-03

50

Tues

day

19

-Aug

-03

Fed

pig

was

te fr

om S

SS fo

r the

firs

t tim

e.

490

Wed

nesd

ay

20-A

ug-0

3 O

pene

d ho

t wat

er p

ump

wid

e op

en y

este

rday

. 49

0

Thur

sday

21-A

ug-0

350

1534

7

Frid

ay

22-A

ug-0

3 O

pene

d D

SR

1 he

ater

to D

SR

2 at

10:

00 a

m.

Exp

losi

on.

53

15

046

Sat

urda

y

23-A

ug-0

351

8090

Sun

day

24

-Aug

-03

4880

90

Mon

day

25-A

ug-0

3 Tu

rned

hea

ters

bac

k on

with

doo

r ope

n.

45

80

90

Tues

day

26

-Aug

-03

4880

90

Wed

nesd

ay

27-A

ug-0

3 H

eate

r bre

aker

faile

d - s

witc

hed

brea

kers

- fo

und

skin

t wire

. 50

8090

19

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yTh

ursd

ay

28

-Aug

-03

5180

90

Frid

ay

29

-Aug

-03

5714

800

Sat

urda

y

30-A

ug-0

359

0

Sun

day

31

-Aug

-03

580

Mon

day

01

-Sep

-03

570

Tues

day

02

-Sep

-03

560

Wed

nesd

ay

03

-Sep

-03

550

Thur

sday

04-S

ep-0

355

0

Frid

ay

05

-Sep

-03

540

Sat

urda

y

06-S

ep-0

355

0

Sun

day

07

-Sep

-03

550

Mon

day

08

-Sep

-03

550

Tues

day

09

-Sep

-03

540

Wed

nesd

ay

10

-Sep

-03

550

Thur

sday

11-S

ep-0

355

1480

0

Frid

ay

12-S

ep-0

3 N

ot g

assi

ng e

xcep

t for

slig

ht b

ubbl

ing.

56

1480

0

Sat

urda

y

13

-Sep

-03

Feed

ing

5614

800

Sun

day

14-S

ep-0

3 Fe

edin

g56

1480

0

Mon

day

15-S

ep-0

3 W

aitin

g fo

r Hur

rican

e Is

abel

la -

mm

inor

gas

sing

. 56

1480

0

Tues

day

16-S

ep-0

3 D

isch

argi

ng 5

dru

ms

- gas

sing

ver

y w

ell t

hru

sam

ple

port.

56

1480

0

Wed

nesd

ay

17

-Sep

-03

5614

602

Thur

sday

18

-Sep

-03

Isab

ella

due

in th

is A

M.

55

14

602

Frid

ay

19

-Sep

-03

5534

532

Sat

urda

y

20-S

ep-0

354

3453

2

Sun

day

21

-Sep

-03

5434

532

Mon

day

22-S

ep-0

3 O

PE

N te

am e

valu

atio

n 55

3453

2

Tues

day

23

-Sep

-03

5434

532

Wed

nesd

ay

24

-Sep

-03

5424

074

Thur

sday

25-S

ep-0

355

2407

4

20

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yFr

iday

26-S

ep-0

355

8682

Sat

urda

y

27-S

ep-0

354

8682

Sun

day

28

-Sep

-03

5486

82

Mon

day

29

-Sep

-03

5386

82

Tues

day

30

-Sep

-03

5386

82

Wed

nesd

ay

01

-Oct

-03

5519

387

Thur

sday

02-O

ct-0

364

1938

7

Frid

ay

03

-Oct

-03

6419

387

Sat

urda

y

04-O

ct-0

3-

1938

7

Sun

day

05

-Oct

-03

-19

387

Mon

day

06

-Oct

-03

6219

387

Tues

day

07

-Oct

-03

6219

387

Wed

nesd

ay

08

-Oct

-03

-19

387

Thur

sday

09-O

ct-0

361

1938

7

Frid

ay

10

-Oct

-03

6111

988

Sat

urda

y

11-O

ct-0

359

1198

8

Sun

day

12

-Oct

-03

5711

988

Mon

day

13-O

ct-0

3 B

egan

redu

cing

vol

ume

in D

SR

2 to

enh

ance

gas

pro

duct

ion.

54

0

Tues

day

14-O

ct-0

3 R

educ

ing

volu

me

(by

disc

harg

ing)

53

0

Wed

nesd

ay

15-O

ct-0

3 R

educ

ing

volu

me

500

Thur

sday

16

-Oct

-03

Red

ucin

g vo

lum

e51

0

Frid

ay

17

-Oct

-03

Red

ucin

gvo

lum

e54

0

Sat

urda

y

18

-Oct

-03

Red

ucin

g vo

lum

e56

0

Sun

day

19

-Oct

-03

Red

ucin

gvo

lum

e60

0

Mon

day

20-O

ct-0

3 R

educ

ing

volu

me

- OP

EN

team

eva

luat

ion

60

0

Tues

day

21-O

ct-0

3 P

ut b

oxes

on

heat

er c

oils

. 59

0

Wed

nesd

ay

22-O

ct-0

3 La

st o

f mas

s di

scha

rges

will

take

pla

ce th

is w

eeke

nd -

norm

al fe

edin

g ne

xt w

eek.

57

0

Thur

sday

23

-Oct

-03

Cal

led

FCI a

bout

DSR

2 m

eter

- w

ill s

end

out t

echn

icia

n.

55

0

Frid

ay

24

-Oct

-03

Feed

ing

agai

n54

1406

0

21

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yS

atur

day

25

-Oct

-03

5214

060

Sun

day

26

-Oct

-03

5214

060

Mon

day

27

-Oct

-03

5214

060

Tues

day

28

-Oct

-03

5314

060

Wed

nesd

ay

29

-Oct

-03

5214

060

Thur

sday

30-O

ct-0

351

1406

0

Frid

ay

31

-Oct

-03

New

DSR

2 m

eter

inst

alle

d 52

3893

1406

0

Sat

urda

y

01-N

ov-0

354

7182

1406

0

Sun

day

02

-Nov

-03

5832

492

1406

0

Mon

day

03

-Nov

-03

6026

883

1879

5

Tues

day

04

-Nov

-03

6227

361

1879

5

Wed

nesd

ay

05

-Nov

-03

6264

0018

795

Thur

sday

06-N

ov-0

361

1550

318

795

Frid

ay

07

-Nov

-03

6093

618

795

Sat

urda

y

08-N

ov-0

359

4490

618

795

Sun

day

09

-Nov

-03

5940

274

1879

5

Mon

day

10

-Nov

-03

5917

708

1879

5

Tues

day

11

-Nov

-03

5941

222

446

Wed

nesd

ay

12

-Nov

-03

580

2244

6

Thur

sday

13-N

ov-0

358

022

446

Frid

ay

14

-Nov

-03

5728

548

3749

2

Sat

urda

y

15-N

ov-0

358

5413

237

492

Sun

day

16

-Nov

-03

5881

449

3749

2

Mon

day

17

-Nov

-03

5858

517

3749

2

Tues

day

18

-Nov

-03

5845

058

3749

2

Wed

nesd

ay

19

-Nov

-03

5671

478

3749

2

Thur

sday

20-N

ov-0

358

8008

652

489

Frid

ay

21

-Nov

-03

5781

547

2877

7

Sat

urda

y

22-N

ov-0

358

5924

428

777

22

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yS

unda

y

23-N

ov-0

357

7535

928

777

Mon

day

24

-Nov

-03

5863

995

3464

7

Tues

day

25

-Nov

-03

5736

439

4949

6

Wed

nesd

ay

26

-Nov

-03

5735

638

4587

9

Thur

sday

27-N

ov-0

357

3559

645

879

Frid

ay

28

-Nov

-03

5625

734

4587

9

Sat

urda

y

29-N

ov-0

355

645

879

Sun

day

30

-Nov

-03

550

0

Mon

day

01

-Dec

-03

570

0

Tues

day

02

-Dec

-03

560

0

Wed

nesd

ay

03

-Dec

-03

560

0

Thur

sday

04-D

ec-0

357

110

0

Frid

ay

05

-Dec

-03

5545

845

879

Sat

urda

y

06-D

ec-0

355

384

0

Sun

day

07

-Dec

-03

5516

20

Mon

day

08

-Dec

-03

5515

40

Tues

day

09

-Dec

-03

550

0

Wed

nesd

ay

10

-Dec

-03

5549

0

Thur

sday

11-D

ec-0

355

10

Frid

ay

12

-Dec

-03

564

0

Sat

urda

y

13-D

ec-0

356

262

0

Sun

day

14

-Dec

-03

5584

40

Mon

day

15

-Dec

-03

5543

80

Tues

day

16

-Dec

-03

5318

60

Wed

nesd

ay

17

-Dec

-03

5316

0

Thur

sday

18-D

ec-0

353

00

Frid

ay

19

-Dec

-03

520

0

Satu

rday

20

-Dec

-03

No

mor

e sw

ine

was

te a

vaila

ble.

53

0

0

Sun

day

21

-Dec

-03

530

0

23

Day

D

ate

Com

men

tsA

ve.

Tem

p

Bio

gas

(CH

4)

mea

sure

d Th

eore

tical

C

H4

prod

(T

echn

olog

y su

pplie

r's d

aily

ope

ratio

n lo

g)

C0

L/da

y

L/da

yM

onda

y

22-D

ec-0

352

00

Tues

day

23

-Dec

-03

520

0

Wed

nesd

ay

24

-Dec

-03

5314

70

Thur

sday

25-D

ec-0

354

00

Frid

ay

26

-Dec

-03

5666

30

Sat

urda

y

27-D

ec-0

357

686

0

Sun

day

28

-Dec

-03

5617

90

Mon

day

29

-Dec

-03

5776

80

Tues

day

30

-Dec

-03

5838

10

Wed

nesd

ay

31

-Dec

-03

5812

00

Thur

sday

01-J

an-0

459

953

0

24

CH

4 Pr

oduc

tion

- OR

BIT

(HSA

D)

0

1000

0

2000

0

3000

0

4000

0

5000

0

6000

0

7000

0

8000

0

9000

0

9/11/1903

9/18/1903

9/25/1903

10/2/1903

10/9/1903

10/16/1903

10/23/1903

10/30/1903

11/6/1903

11/13/1903

11/20/1903

11/27/1903

Dat

e

CH4 Production (L/day)

CH

4 pr

oduc

tion

(mea

sure

d)

CH

4 pr

oduc

tion

(The

o)

__

A

ppen

dix

Figu

re 1

. O

RB

IT M

etha

ne P

rodu

ctio

n, T

heor

etic

al A

nd A

ctua

l, A

s Det

erm

ined

By

T

echn

olog

y Pr

ovid

er

25

App

endi

x T

able

4.

Tec

hnol

ogy

Prov

ider

’s D

aily

Ope

ratio

n L

og –

Fee

dsto

ck A

dditi

on a

nd D

iges

tate

Dis

char

ge D

ata

Dat

e C

omm

ents

Fe

edst

ock

Dis

char

geM

ean

(Tec

hnol

ogy

supp

lier's

dai

ly o

pera

tion

log)

lb

s kg

lb

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30

ORBIT US ARMY Dem/Val Final Report 25 Feb 2004

Executive Summary Military Need The technology demonstration and validation described in this report responds to the Army’s pollution prevention requirement on recycling, A (3.5.c). The system tested and proven in this Dem/Val also has considerable potential to fulfill the Zero Footprint Camp initiative’s need for a transportable system for overseas deployments. That goal is priority number one for the Army. Dem/Val Background Between August 2, 2002 and November 6, 2003, HSAD was tested and evaluated for potential Army use under a contract issued to Unisphere Inc., an Army contractor responsible for assessing, developing and commercializing dual use technologies under the direction of Office of the Assistant Secretary of the Army (Installations and Environment) (ASAI&E). Unisphere subcontracted all tasks in the “HSAD Demonstration/Validation Test and Evaluation Plan” (DCC-W Contract No.: DASW01-02-0033) to Organic Biotechnologies, LLC (ORBIT), a company established to develop HSAD for ultimate use by military and commercial customers. ORBIT performed all test plan tasks at its near-commercial scale plant 10 miles west of Clinton, NC and 35 miles east of Fort Bragg. Food waste from Army mess halls and paper waste were picked up at Fort Bragg, transported to the ORBIT plant and converted into two value-added products: biogas and a pathogen free digestate that is appropriate for use as a soil amendment.

History of HSAD In The U.S. The commercial scale HSAD plant near Clinton, NC is believed to be the first of its kind in the United States. Thermophilic anaerobic digestion has flourished in Europe for the last two decades. Unlike its U.S. counterpart, most European technology is based on designs adapted, for the most part, from wastewater treatment systems. The European industry is fostered by high electricity rates and high landfill tipping fees. Recent attempts by firms there to penetrate the U.S. market have not succeeded. Lab scale experiments with HSAD began at the National Renewal Energy Laboratory (NREL) in Golden, CO in the late 1980s. Over the next decade, NREL spent $8.5 million developing the technology. To breed a thermophilic consortium, NREL gathered bacteria from volcanic “hot spots” like Old Faithful, the Chicago Stockyards and municipal sewer systems where unusual species had proven their survivability. Gradually, as the consortium developed, so did a new mechanical approach. The basic mechanical problem associated with HSAD was the feeding, mixing, agitation, and discharge of 35% to 40% solids. The pug tine technology resolved the issue of how to mix high solids materials without damaging the microbial films. A food industry ribbon blender was found to be adequate for mixing the high solids feed stocks, and screw

31

conveyors were found suitable for feeding the high solids materials into the digester after studies at Colorado State University resulted in altering the screws to be pneumatically inserted into the digester prior to feeding. Without insertion of the feed screw into the digester prior to feeding, plugging of the feedscrew was frequent and problematic. In 1996 NREL funded construction of a HSAD pilot plant in Stanton, CA. It was fully functional for only a short time, but it demonstrated that HSAD could produce copious amounts of biogas using mechanics adapted from mixing and agitation systems used in the mining and food processing industries. The new biological and mechanical approach represented a complete departure from the conventional wastewater treatment systems used for more than a century. It offered order of magnitude advances in the form of solids processing up to 15 times higher, and digestion rates up to four times faster. Supplanting large amounts of water with solids shrank the HSAD system footprint and capital construction costs substantially when compared to conventional systems. Dem/Val Test Results In 12 weeks of continuous Steady State testing that ended November 6, 2003, HSAD substantially exceeded all key baseline Measures of Merit defined in an Army-approved Test Plan, demonstrating that the military can significantly benefit from widespread utilization of this innovative technology. Moreover, its low capital cost, mechanical simplicity and overall efficiency make HSAD a prime candidate for lowering Army operational costs, enhancing environmental performance and reducing military dependency on high-cost energy produced from fossil fuels. Dem/Val performance highlights for HSAD: • Produced methane at a rate of 665,926 liters of methane per ton of food waste

averaging 650 gms/kgm COD. • Averaged 11.85 decatherms of methane per ton of feedstock – enough to meet the

daily requirements of 56.61 average U.S. homes. • Methane production averaged 798 L-CH4/kgm-MVS/day. • Averaged 63.13% methane in total biogas produced during the life of the Dem/Val

(and 67% over the last six weeks). • Complete (99.9%) pathogen kill due to prolonged pasteurization at 55oC, and

although the digestate is not classified as biosolids, it meets the same requirements set for classification as 40 CFR 503 Class A biosolids.

• Independent lab tests confirming that HSAD digestate is an excellent organic soil amendment with the properties of slow release nitrogen fertilizers (priced, generally, three times higher than regular nitrogen).

• Solids processed at approximately 34% -- about 15 times higher than is possible for the low solids systems used at Army and municipal wastewater treatment plants. Elimination of the excess water dramatically reduces HSAD’s footprint and subsequent capital construction costs.

• No offensive odors from the HSAD system; only minimal odor associated with loading and unloading.

• No operational problems with ammonia, nor ammonia emissions. • No mechanical interruptions during the Dem/Val period.

32

• An economic study, conducted as part of the test and evaluation of HSAD, projects, based on actual operating data and experience, an 18.8% internal rate of return from a 6.5 ton per day system processing Army organic waste on or near Ft. Bragg. The economic study in this report does not contemplate use of either the screw press or liquid fertilizer storage.

• The Dem/Val test demonstrates that the HSAD process is resilient in nature, can be operated by one trained worker, and is extremely efficient at producing a large amount of energy from a relatively small amount of waste products.

Tables 1, 2 and 3 provide Critical Measures of Merit and actual results for HSAD’s Dem/Val performance using technical, environmental and economic criteria.

33

Table 1- Critical Technical HSAD Measures of Merit

Critical Measure Dem/Val Benchmark Dem/Val Result

Average Biomass Conversion Efficiency (BCE) 55-60%% 65.4%

Chemical Oxygen Demand (COD) Total Destruction 60% 87%

Methane Production-NL-CH4/kgm-COD @100% Conversion 330 525

Average Methane Content in Biogas, % 55% 63.13%

Maximum Daily Methane Content in Biogas, % 55% 79.03%

Average Daily Methane Production, NLM 105,000 332,963

Average Organic Loading Rate, gms-VS/kgm/day 5.0 5.17

Maximum Organic Loading Rate, gms-VS/kgm/day 5.0 8.53

Average Digestate pH 6.6 to 8.2 7.75

Digester Internal Temperature 50oC to 65oC 52oC

Average COD, gms/kgm (wet) 500 650

Pathogen Kill >99% 99.9%

.

34

Table 2-Critical Environmental HSAD Measures of Merit

Critical Measure Dem/Val Benchmark Dem/Val Result

Waste spills in transport None None

Ensure Containment of Food Waste Until Processing Begins

Maintain in closed containers until

processing begins

Food Wastes contained in same containers until

processed

Prevent Liquid Runoff No runoff from liquid tanks No liquid runoff

Prevention of Odor No discernable odor No odor

Compliance with NC DENR Environmental Regulations Compliance Full Compliance

Table 3- Critical Economic HSAD Measures of Merit

Title Dem/Val Operation Benchmark Dem/Val Achievement

Internal Rate of Return Positive 18.8%

Reduced Army operating costs Show potential to lower May lower by one third or

more

Capital construction costs Identify potential reductions Design innovations to lower substantially

Organic fertilizer product Prove production viability Excellent qualities

HSAD an Innovative Technology The demonstration defined significant innovations in four areas: 1) A new methodology for film transfer of end products of different bacteria in the complete consortium; 2) The mechanical system – including mixing system; hydraulically operated ratchet assembly; and the screw feeder; 3) Operational knowledge that could only be developed through trial and error experience; and 4). a new transportable design for a stand-alone system that will facilitate on-farm deployments and deployments on military bases. Several of these innovations will be patented and are protected currently as trade secrets.

HSAD is truly innovative anaerobic technology based on the theory of film transfer of digestive products between anaerobic microbes in a solids environment, and as such, HSAD is significantly different from any other anaerobic system in that it utilizes sub-rpm, low-shear, pug-tine agitation to protect and preserve the bacterial films required for efficient digestion, maintain constant contact between the hydrolytic bacteria and the food substrate for rapid breakdown and solubilization of polymers, and a bacterial consortium that has been adapted to concentrations of ammonia that exceed 4,000 ppm.

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The Future of HSAD When the Dem/Val period ended on November 6, ORBIT doubled the feed rate of Army food waste to see how the system would respond. It reacted by producing more than 500,000 liters of methane in the next 24-hour period. Feeding at this new organic loading rate continued for over the next week with no negative effects, thus refuting the notion that organic loading rates must be increased very slowly. Results of this Dem/Val proved that HSAD is relatively simple to manage biologically and mechanically. The system’s operating efficiency, low capital cost and high internal rate of return point the way to broad adoption of the technology by military and commercial customers. Even more important is the fact that HSAD addresses what many believe is the greatest environmental problem the U.S. currently faces: i.e. rising amounts of and costs associated with disposal of organic wastes that pollute aquifers, watersheds and the air we breathe.

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