Poultry manure as a substrate

for methane fermentation:

problems and solutions
Robert Mazur Ph.D., Jakbu Mazurkiewicz M.Sc. eng.
Andrzej Lewicki M.Sc. Eng, Sebastian Kujawiak M.Sc. Eng

Poznan University of Life Sciences

Poland

Number of agricultural holdings, by NUTS 2 regions, 2010 [thousand

holdings], by NUTS 2 regions, 2010 Eurostat.

Some facts about Poland

National and European obligations for Poland before 2020:
i) 15% of reduction of CO2 emission
ii) 15% of energy produced from renewable energy
sources (RES)
. but:
Relatively bad geographical conditions for investment in
hydro- and wind power
In consequence:
Biomass used as renewable energy source seems to be one
of the main factors which can help to reach Polish
obligations at 2020

The potential of biomass from

agricultural sources in Poland
1. The total technical potential for the production
of agricultural biogas from manure in Poland is
674 million m3 of biogas i.e. 26,2 PJ, which
represents approximately 21% of the
theoretical capacity from all RES in Poland.
2. The economic potential of agricultural biogas is
even more limited.

The potential of biomass from

agricultural sources in Poland
The calculation includes the sources such as:
Cattle farms with stocking density more than 100
animals
Pig farms with stocking density more than 500
animals
Poultry farms with stocking density of over
5000 birds.

Poultry farms with stocking density

of over 5000 birds

Laying hens population - annual data

5 0.000
4 9.000
4 8.000
4 7.000
4 6.000
4 5.000
4 4.000
4 3.000
4 2.000
2003

2004

2005

2006

2007

2008

2009

PL - Poland [thous.]

Laying hens population in Poland - annual data (Eurostat)

2010

Laying hens population - annual data

7 0.000

6 0.000

5 0.000

4 0.000

3 0.000

2 0.000

1 0.000

00
2003

2004

2005

DE - Germany

2006

FR - France

2007

2008

2009

2010

PL - Poland

Laying hens population in De., Fr., Pl. in thousand - annual data (Eurostat)

Production of chicken meat, 2012

14%

29%

13%
12%

10%
11%

Fr

UK

Pl

De

11%

Es

It

OtherMembers

Production of poultry meat, 2012 (% share of EU-28 total) AgriPB13.png

Production of chicken meat, 2012

Poland already surpassed UK last year as
the leading producer of chicken meat in the
EU.

Poultry production in Poland

160000

140000

Thousand

120000

100000

80000

60000

40000

20000

0
1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

Poultry production in Poland 2012

Chicken manure biogas potential

The enormous potential of biogas production
also results from the possibility of using manure
from poultry farms.
Chicken manure gas efficiency (about 32% dry
matter) is estimated at 70-90 m3 of biogas per
tone of FM (with 60% methane).
Poland is one of the leading poultry producers in
Europe, with some large chicken farms with up
to 2.000.000 birds for meat or egg production.

Chicken manure biogas potential

According to data from Professor Zbigniew Dobrzaski
(Wroclaw University of Life Sciences), the annual
amount of manure generated by poultry consists of 2.7
million tons of chicken manure, 0.72 million tons of
turkey manure and nearly 0.38 million tons of other
poultry manure.
The result is a composite theoretical performance of 170,
38 and 20 million m3 of methane per year, or a total
electrical capacity of over 105 MW. With a standard
working time of cogeneration units of 8.000 hours, these
produce 840 MWh of energy per year.

Problems with biogas production

based on chicken manure:
1. In Europe, there is no technology fermenting
100% chicken manure
2. Biogas plants that generates biogas based on
chicken manure only, have a very low yield of
methane (China).
3. The Wabio Company - has developed a 5
stages (5 chamber) technology, operating on
highly concentrated chicken manure (too
expensive and not profitable for investors).

What the sources of problems in biogas

fermentation of chicken manure:
Excessive concentration of nitrogen in the
substrate
Too much mineral matter
Antibiotics and steroids might be a serious
threat to many cultures of methane
fermentation bacteria
Excessive
concentration
of
sulfur
compounds (from proteins)

Problems with poultry manure methane

fermentation
All of the above factors should lead
potential investors to particular care in
investments associated with the production
of biomethane from chicken manure.
The scale of production of chicken manure
in Poland and Europe leads to a deep take
an interest in this market, and the possibility
of management of this type of substrate for
energy purposes.

Poultry manure and poultry litters:

Poultry manure is the organic waste
material from poultry consisting of animal
feces and urine.
Poultry litter refers to the manure mixed
with some of the bedding material or litter
(wood shavings or sawdust) and feathers.

Poultry manure from chicken farm in China

Poultry litter from chicken farm in Poland

Nitrogen is the main inhibitor of the

process
Many authors report that ammonium nitrogen
(i.e. the dissolved form of ammonia to form
NH4+) becomes an inhibitor for the proper
development/propagation of methane bacteria
and therefore inhibits the production of
biomethane.
In concentration of 2.7 g/kg of solution.

Average nutrient composition of poultry

manures
Manure Type

Total N

Broiler

Ammonium Phosphorus Potassium

(as P2O5) (as K2O)
(NH4-N)
lb/ton

Fresh (no litter)

26

10

17

11

Broiler house litter

72

11

78

46

Breeder house litter

31

54

31

Stockpiled litter
Layer
Fresh (no litter)
Undercage scraped
Highrise stored

36

80

34

26
28
38

22
31
56

11
20
30

Liquid slurry
Anaerobic lagoon sludge

62
26

59
92

37
13

Anaerobic lagoon liquid

180

45

265

1Source:

6
14
18
lb/1,000 gallons
42
8
lb/acre-inch
155

Biological and Agricultural Engineering Dept., North Carolina State University, as reported in "Poultry Manure
as a Fertilizer Source," 1997, Soil Facts fact sheet AG 439-5 authored by J.P. Zublena, J.C. Barker, and T.A.
Carter,http://www.soil.ncsu.edu/publications/Soilfacts/AG-439-05/

Chicken manure and poultry

litter case study
The study on chicken manure in the Laboratory
of Ecotechnologies in Poznan University of Life
Sciences
The study of biogas efficiency from chicken
manure and poultry litter
The study was carried out in bioreactors in
accordance with DIN 38 414

8
7
6

11
9

1
2

10

12

Figure: Scheme of bioreactor (Section of 5-chambers): 1. Water heater with a

temperature controller, 2. Isolated pipes with heating liquid, 3. The water
jacket at a temperature of 36-38oC,
4. Bioreactor with a load capacity of 1,4-2 dm3, 5. Biogas tank, 6. Shut-off
valves, 7. Gas Flow Meters, 8. Gas analyzers (CH4, CO2, NH3, H2S, O2), 9. pH
sensors, 10. Temperature sensor, 11. The control panel and registration, 12.
Magnetic stirrers for batch mixing.

Methods and Materials

The physical-chemical parameters of
chicken manure.
Dry matter: 32,2%
Total nitrogen concentration 18,1 g/kg of
FM, ammonium nitrogen 13,94 g/kg of
FM.
pH 8,1

The biogas laboratory facilities at our

University

Methods and Materials

Water dilution method for chicken manure:
In experiment used chicken manure diluted in
five levels up to: 10, 8, 6, 4 and 2% of dry
weight.
After dilution, was added 10% fermentation
bacteria inoculates. As a result of different levels
of dilution of the chicken manure, there were
obtained pulpy with different concentration of
total and ammonium nitrogen.

The biogas laboratory facilities at our

University

The N concentration [g / kg FM]

Changes in the content of total nitrogen and ammonia,

depending on the dilution of chicken manure
6

N-tot

N-NH4
4,38

3,52
2,81

2,7 g/kg

1,75

0,88

1
0
10%

8%

6%
Dry matter of pulpe [%]

4%

2%

Production of biogas and methane, depending on the

dilution and calculated on the dry matter of the pulp

Biogas efficiency [m3/t DM]

450
400
350

biogas
methane

300
250
200
150
100
50
0
10%

8%

6%

Dry matter of pulp [%]

4%

2%

The N concentration [g / kg FM]

Changes in the content of total nitrogen and ammonia,

depending on the dilution of chicken manure with bacteria,
characterized with a higher tolerance to nitrogen content
6

N-tot

N-NH4
4,12

3,45
2,94

2,7 g/kg

1,63
1,03

1
0
10%

8%

6%

Dry matter of pulp [%]

4%

2%

Production of biogas and methane, depending on the dilution

and calculated on the fresh weight of the pulp with bacteria,
characterized with a higher tolerance to nitrogen conten

Biogas efficiency [m3/t DM]

450
400

biogas

350

methane

300
250
200
150
100
50
0

10%

8%

6%

Dry matter of pulpe [%]

4%

2%

Production of biogas and methane, depending on the

dilution and calculated on the fresh weight of the pulp with
regular inoculum and inoculum containing bacteria with a
higher tolerance to nitrogen
Methane production [m3/t FM]

300
250

without bacteria
with added bacterial inoculum

200
150
100
50
0
10%

8%

6%

Dry matter of pulpe [%]

4%

2%

The cumulative methane production [m3/t DM]

Production of biogas and methane rom

different type of poultry litter
300
Ch. M. 9%

T. L. 9%

Ch. M. 6%

250
200
150
100
50
0
0

10

20

30

40

50

Fermentation time [days]

Ch.M. - chicken manure, T.L. turkey litter

60

70

The cumulative methane production [m3/t DM]

Production of biogas and methane rom

different type of chicken manure
300
Ch. M. 9%
Ch. M. 6%

250

100%
(264)

90%
80% (235)
(211) 39 days

200

60 days

35 days

150

100%
(181)

90%
(163)

80%
(145) 46 days

100

63 days

41 days

50
0

10

20

Ch.M. - chicken manure

30

40

50

Fermentation time [days]

60

70

Efficiency of biogas production [m3/t DM]

Production of biogas and methane rom

different type of poultry manure /litter
450

biogas

400

methane

350
300
250
200
150
100
50
0

Ch.M. 6%

Ch.M. 9%

T.L. 6%

Type of poultry manure /litter

T.L. 9%

Water consumption in the process

of the substrate dilution
1 ton of chicken manure to be diluted to

32,2%

of dry matter requires

m3 of water

1 ton of chicken manure to be diluted to

10%

of dry matter requires

2,2

m3 of water

1 ton of chicken manure to be diluted to

8%

of dry matter requires

m3 of water

1 ton of chicken manure to be diluted to

6%

of dry matter requires

4,4

m3 of water

1 ton of chicken manure to be diluted to

4%

of dry matter requires

7,1

m3 of water

1 ton of chicken manure to be diluted to

2%

of dry matter requires

15,1

m3 of water

The biogas plant operating on 100%

chicken manure in China

Chinese solution for the production

of biogas from poultry manure

Raw chicken manure from farm

Raw chicken manure from farm

Raw chicken manure from farm

Digested poultry manure

Digested poultry manure facilities

Digested poultry manure facilities

Dried digested poultry manure as

a valuable fertilizer

Dried digested poultry manure

facilities

Dried digested poultry manure

as a valuable fertilizer

The first plug flow digester of

chicken manure from the 1990

Biogas plan - Complex of digesters

Biomethane to the gas network

Compressed biogas station

Pressure pump station

The final utilization of the biogas

Field application of afterdigest

fertilizer

Field application of afterdigest

fertilizer

Greenhouse crop production

Outloock for future

To ensure an effective biogas production process
based on poultry litter and poultry manure should
be:
To develop an appropriate method of N stripping
from the substrate and percolate in the recycling
(chemical or biological technologies).

Outloock for future

It should be selected appropriate bacteria highly
tolerant to high concentrations of NH3 in the
substrate, and
other
negatives factors
(antibiotics and steroids)
Whenever possible, use a method of cosubstrates to balance the ratio of C:N (100:33).
It should be introduced the appropriate rearing
conditions at the poultry farm in order to obtain
stable parameters for the final chicken manure

Thank you for your attention

Vielen Dank fr Ihre Aufmerksamkeit