Cayuga County Regional Digester: Vision Becomes Reality. Final Report

Abstract

With an average herd size of 113 mature cows, Cayuga County is home to 280 dairy farms and 31,500 dairy milking cows producing approximately 855 million gallons of milk per year. The Cayuga Dairy industry is a major contributor to the countys economy, employing nearly 1200 people, while generating $140,000,000 of revenue from sale of milk alone. At the same time, the Cayuga County dairy industry also produces 5.7 million gallons of manure daily: (a) Nearly 34% of this manure is produced on smaller farms. (b) Digesters are expensive pieces of equipment and require attention and care. ( c) The on-farm digester systems have fairly long payback (>10 years) even for larger CAFO farms (>1000 milking cows). In 2005, Cayuga County Soil and Water Conservation District (The District), a Public Agency under Cayuga County, decided to undertake a centralized community digester project. The primary goal of the project was to develop an economically sustainable model, under the auspices of The District to address manure management issues facing the smaller dairies, improve the water quality and improve the quality of life for Cayuga County residents. It is believed that the District has accomplished this goal by completing construction of Cayuga County Regional Digester on a parcel of land behind the Cayuga County Natural Resource Center located at 7413 County House Road in the Town of Sennett in Cayuga County, New York. The digester facility consists of the following major components. 1. Transfer Station: This an indoor truck bay, where 35,000 gallons of manure from three local farms, 8,500 gallons of liquid organic food-processor waste, and 1,200 gallons of brown grease are unloaded from tanker trucks and the digested slurry is loaded onto the tanker trucks for delivery back to the participating farms. 2. Anaerobic Digester: The project utilizes a hydraulic mix anaerobic digester, a unique design that has no internal moving parts for mixing. The digester, which operates at mesophilic temperatures, is designed to process the daily feedstock and produce 220,000 SCF2 of biogas per day. The digester also produces 44,000 gallons of digested slurry per day. 3. Biogas Conditioning System: The plant employs a biological biogas conditioning system to remove the H2S and moisture contents of the biogas and prepare it to be used by the plant generation system. 4. Combined Heat and Power System (CHP): This is a 633kW high efficiency biogas-fired GE-Jenbacher model JMS-312 GS-NL reciprocating engine cogeneration system. The heat recovery system incorporated into the package is designed to capture the waste heat from the engine exhaust, the jacket cooling water and the engine oil circuit. 5. Electrical Substation and Power Distribution Systems: An electrical distribution system has been constructed on-site that aggregates the electrical service of the different county buildings on the District campus into a county owned electric distribution system that is interconnected with the CHP and the local electric grid. The electrical system is designed, in accordance with the utility guidelines, to allow grid-parallel operation of CHP and provide for import and export of electric power. 6. Thermal Energy Distribution System: The heat recovery system has been integrated into a high temperature water distribution system that distributes the heat to the thermal circuits for the anaerobic digester facility. Additional piping has also been installed to transfer the remaining thermal energy to other county buildings on the campus. On a daily basis, the plant will co-process 35,000 gallons of manure from local dairy farms, 8,500 gallons of food-processor waste and 1,200 gallons of brown grease to produce 200,000 ft3/d of biogas and 44,000 gallons of pathogen-free nutrient-rich digested slurry for agricultural use by farms and in the local area.The biogas fueled CHP produces 5,157,000 kWh of electricity and 19,506 dekatherms of thermal energy per year. Electrical power generated by the cogeneration system powers all the buildings on the Cayuga County campus and any surplus power is exported to the grid under a power purchase agreement. Heat recovered from the cogeneration system will be used to maintain the temperature of the process equipment and the excess will be transported to the Cayuga County Public Safety Building to offset purchase of fossil fuel to fuel the boilers. The majority of plant operations are unmanned and automated. However, the plant will have a small staff of well-trained personnel to coordinate the feedstock deliveries and shipments, supervise the day-to-day operation, monitor the systems and perform maintenance, maintain a safe and reliable operation and to respond to emergencies.