Szogi was with North Carolina State University when the
trio first planned the system in 1997.
A combination of technologies developed by companies in
the United States, Spain, and Japan, as well as by ARS researchers,
the system comprises tanks and staging areas laid out over 200 feet.
In three stages, it separates solids and liquids, removes ammonia, recovers
soluble phosphorus, and processes the solids into plant fertilizer.
A patent on the system has been allowed (under U.S. Patent
Application Serial No. 09/903,620, filed July 13, 2001).
The year-long evaluation was conducted using a full-scale
version of the system built at Goshen Ridge Farm, a 4,360-head swine-finishing
facility in Mount Olive, North Carolina. It was implemented by the inventors
and the Clinton, North Carolina-based private firm Super Soil Systems
USA. Construction was part of an agreement between Smithfield Foods
of Smithfield, Virginia; Premium Standard Farms of Kansas City, Missouri;
and the North Carolina Attorney General's office to use environmentally
superior technology to replace current waste lagoons.
The researchers tested the system's ability to eliminate
animal-waste discharge to surface and ground watersalong with
related release of ammonia, odor, and pathogens. They also evaluated
its ability to stem soil and groundwater contamination by nutrients
and heavy metals.
Three Revolutionary Processes
The system performs three critical processes in animal-waste management:
It separates solids and liquids from swine wastewater while recovering
organic matter; it removes ammonia from wastewater, using acclimated
nitrifying bacteria; and it transforms phosphorus removed from wastewater
into a solid, marketable fertilizer while converting leftover effluent
into an environmentally friendly liquid crop fertilizer.
"Results showed that this system can have a great impact in animal-waste
treatment," says Szogi.
How great an impact?
It removed more than 97 percent of total suspended solids from wastewater
during the tests. It stripped the water of 95 percent of its total phosphorus,
99 percent of its ammonia, 98 percent of its copper, 99 percent of its
zinc, more than 99 percent of its biochemical oxygen demand, and more
than 97 percent of its odor-causing components.
The reduction in fecal microorganisms achieved in this system resulted
in disinfected effluent. Says microbiologist Patricia Millner, a project
cooperator from ARS's Environmental Microbial Safety Laboratory in Beltsville,
Maryland, "This prevents dispersion of pathogens into soil, water,
or air when the treated effluent is sprayed onto fields or recycled
into storage ponds."
Indeed, the evaluation site's old wastewater lagoon was converted into
clean, aerated water. "It changed color, from brown to blue,"
Minimizing the impact of livestock waste on the environment is one
of U.S. agriculture's major challenges. With swine facilities, the problem
is compounded when nutrient-rich waste is flushed into lagoons and then
applied to cropland. Problems arise when more nutrients are applied
than crops or forage can use, causing excess nutrient runoff that can
lead to poor drinking water and oxygen depletion in bodies of water.
The magnitude of this challenge was clear during the evaluation. At
its operating peak during the trial, the system processed waste generated
by more than 4,000 pigs. On average, 12,700 gallons of manurecontaining
176 pounds of nitrogenwere flushed from the complex each day!
A Fully Automated System
The system is fully automated, using sensors integrated to a programmable
logic controller for round-the-clock operation.
In assembly-line fashion, it uses three modules. The firstthe
Ecopurin Solid-Liquid Separation Module, developed by the Spain-based
firm Selco MCquickly separates solids and liquids. "This
conserves much of the organic fraction of the waste," says Hunt,
adding that polyacrylamideshigh-viscosity, water-soluble polymersare
used here for coalescing the solids.
In tests, this module, housed in a building of its own, removed 93
percent of all suspended solids, including heavy metals. It removed
94 percent of zinc and copper and 70 percent of phosphorus from the
wastewater. It also produced 657 tons of separated solid waste that
can be converted to organic plant fertilizer, soil amendments, or energy.
The second step, the biological removal of ammonia, involved the Biogreen
Nitrogen Removal Module developed by Hitachi Plant Engineering and Construction
Company, in Tokyo. "Once solids are removed, a relatively smaller
amount of suspended organic waste remains in wastewater, but it still
contains significant amounts of soluble ammonia and phosphorus,"
says Vanotti. "This biological process consistently removed more
than 95 percent of the ammonia and total organic nitrogen present in
the manure after separationeven during winter, with below-freezing
From there, the wastewater flowed by gravity to the final step, the
Soluble Phosphorus Removal Module, which produces one of the technology's
most beneficial results.
Developed by Vanotti, Szogi, and Hunt, it recovers phosphorus as calcium
phosphate and destroys pathogens through alkaline pH. It also turns
the removed phosphorus into a solid, marketable fertilizer, and it converts
leftover effluent into a liquid crop fertilizer that's more environmentally
friendly than manure.
Over 9 months, this process produced 285 bags of calcium phosphate,
containing 1,160 pounds of phosphorus.
"Overall, it was verifiedat full scalethat the system
is technically and operationally feasible," says Hunt. Adds Szogi,
"It performed well under both cold- and warm-weather conditions."
Says Vanotti, "The innovation can soften the effect of the new
demands regarding modern swine production and environmental sustainability."By
Agricultural Research Service Information Staff.
This research is part of Manure and Byproduct Utilization, an ARS
National Program (#206) described on the World Wide Web at www.nps.ars.usda.gov.
Matias B. Vanotti,
Ariel A. Szogi, and
Patrick G. Hunt are
with the USDA-ARS Coastal
Plains Soil, Water, and Plant Research Center, 2611 W. Lucas St.,
Florence, SC 29501-1241; phone (843) 669-5203, fax (843) 669-6970.
"Blue Lagoons on Pig Farms?" was published in the
issue of Agricultural Research magazine.