{"id":153982,"date":"2024-05-03T10:59:37","date_gmt":"2024-05-03T14:59:37","guid":{"rendered":"https:\/\/www.hajim.rochester.edu\/senior-design-day\/?p=153982"},"modified":"2025-05-02T14:50:03","modified_gmt":"2025-05-02T18:50:03","slug":"ammonia-biofilter-optimization-for-chicken-manure-composting","status":"publish","type":"post","link":"https:\/\/www.hajim.rochester.edu\/senior-design-day\/ammonia-biofilter-optimization-for-chicken-manure-composting\/","title":{"rendered":"Ammonia Biofilter Optimization for Chicken Manure Composting\u200b"},"content":{"rendered":"

Ammonia Biofilter Optimization for Chicken Manure Composting<\/span><\/span><\/p>\n

Authors: Geoffrey Doyle, Jason Maher, and Aidan Shea
\nAdvisor: Professor Kelley \u200b
\nDepartment: Chemical Engineering
\nSponsor: Hal Kreher, Kreher Farms<\/p>\n

Introduction<\/span><\/p>\n

Kreher Farms<\/a>\u00a0is a family-owned and operated poultry and egg farm<\/span><\/span>\u00a0headquartered in Clarence,\u00a0<\/span>NY. It is home to about 60,000 chickens, which produce 5,400 cubic feet of manure each week, which are composted <\/span>over the course of 6 weeks in two large warehouses <\/span>and then sold as fertilizer. Recent years have seen a rise in odor-related complaints <\/span>from neighbors, and recent European regulations on ammonia emissions are <\/span>likely to be mirrored by the U.S. EPA in the coming years, which <\/span>have incentivized Kreher Farms to reduce its ammonia emissions. They have <\/span>developed a wood chip and recycled shipping container (Figure 1). Our\u00a0<\/span>sponsor has requested that we investigate the filtration performance of\u00a0<\/span>biochar, which is prepared by anaerobic pyrolysis of wood, and determine\u00a0<\/span>whether it would be a valuable addition to Kreher Farms’ current system.\u00a0<\/span><\/p>\n

\"\"
Figure 1. Kreher Farm’s current filter is a recycled 40x9x8.5 ft3 shipping container, a wood chip bed supported by plastic mesh, and a 10 hp fan that pulls a vacuum through the bed. The inlet air has about 100 ppm of ammonia.<\/figcaption><\/figure>\n

Our literature review revealed that biochar prepared at high temperatures\u00a0<\/span>and utilized in high moisture environments has an optimal performance of\u00a0<\/span>114 mgNH3\/g biochar, while the adsorption of ammonia onto wood chips\u00a0<\/span>is\u00a0not well studied. Separate studies showed that\u00a0biologically active filters\u00a0<\/span>contain microbes that continuously convert ammonia into nitrates; so long as\u00a0<\/span>the nitrification reaction kinetics (consumption) are faster than air-to-bed\u00a0<\/span>mass\u00a0transfer (adsorption), these systems can be operated indefinitely. This\u00a0<\/span>system is often employed in municipal wastewater treatment systems.\u00a0<\/span>\u200b<\/p>\n

Our experiment attempted to replicate our sponsor’s current\u00a0<\/span>air\u00a0filtration\u00a0conditions and compare them to candidate future designs. The\u00a0<\/span>total mass of adsorbed ammonia was calculated by integrating the ammonia\u00a0<\/span>concentration between the introduction of ammonia into the system to its\u00a0<\/span>steady-state\u00a0saturation time (Equation 1).\u00a0<\/span><\/p>\n

\"\"
Equation 1: Total mass of ammonia adsorbed in a bed, calculated by integrating the difference between the inlet and outlet concentrations. m is the mass of ammonia, M is the molecular weight of ammonia, C is the concentration of ammonia, and t represents time.<\/figcaption><\/figure>\n

Methods<\/span><\/p>\n

Adsorption Column Specifications: <\/span>\u200b<\/p>\n

    \n
  • Four packing materials\u00a0were tested in parallel columns made from 6″ID PVC\u00a0<\/span>piping and plastic mesh disks. Bed #1: 18″ layer of dry wood chips, Bed #2:\u00a0<\/span>4″ biochar layer on top of an 18″ wood chip layer, Bed #3: same as the\u00a0<\/span>second but rinsed daily to maintain moisture, Bed #4: 18″ manure-<\/span>inoculated wood chips, also rinsed daily to maintain moisture. Beds 3 and 4 were kept moist by rinsing with 2L of water before the start of each trial. Beds 1 and 2 reflect the current and intended designs from our sponsor, and Beds 3 and 4 are additional parameters we wanted to test as a result of our literature review.\u00a0<\/span><\/li>\n
  • Dry wood chips and dry biochar were delivered to us by our sponsor. Both were synthesized from pine wood.<\/li>\n
  • \u200bThe wet woodchips were created by letting dry woodchips soak in a water bath for one week. The wet biochar underwent the same process, but needed to be weighed down by an additional beaker of water because it would otherwise float on top of the water and not reach water saturation. The manure-inoculated wood chips were synthesized with the same technique as the wet wood chips, but with about chicken manure mixed in as well in approximately a 4:1 ratio.<\/li>\n
  • In accordance with our literature review, we hypothesized that the Beds\u00a0<\/span>would perform from worst\u00a0to best\u00a0in the order listed above.<\/span>\u200b<\/li>\n
  • The columns simulated a vertical slice of the full-scale design by utilizing the\u00a0<\/span>same volumetric flow rate of air per cross-sectional area, 33.7 ft3\/min\/ft2,\u00a0<\/span>which translated to a total 26.5\u00a0ft3\/min of air\u00a0with 100 ppm ammonia.\u00a0<\/span>\u200b<\/li>\n
  • Sparkfun<\/span>\u00a0<\/span>Quiik<\/span>\u00a0air velocity sensors,\u00a0<\/span>Sparkfun<\/span>\u00a0moisture sensors,\u00a0<\/span>and\u00a0<\/span>Winsen<\/span>\u00a0MQ-137\u00a0ammonia sensors were\u00a0used\u00a0to maintain operating\u00a0<\/span>conditions and measure ammonia concentration.\u00a0<\/span><\/li>\n<\/ul>\n

    \"\"<\/p>\n

    \"A
    Figure 2: (a) P&ID and (b) labelled photograph of our experimental apparatus.<\/figcaption><\/figure>\n
    \"\"
    Figure 4. Adsorption column materials going counterclockwise: (a) dry biochar, (b) dry wood chips, (c) wet wood chips, (d) mesh disk holding up bed materials, (e) soaking process for biochar, submerged in an weighed down by water.<\/figcaption><\/figure>\n
    \"\"
    Figure 5. Exit pipe of Bed 3, showing the positions of the ammonia and wind sensors.<\/figcaption><\/figure>\n

    \"\"<\/p>\n

    \"\"
    Figure 6. (a) Flash evaporation chamber. Droplets of 5% NH4OH solution are dripped onto a hot plate and achieve immediate complete evaporation. An opening in the bottom rear of the evaporation chamber allows air to come through. The mixture of moisture and gaseous NH3, 100 ppm, is then drawn through the white 1.5″ID PVC piping and brought to the bottoms of the columns. (b) Peristaltic pump running at 1.5 mL\/min and storage tank of 5% NH4OH solution.<\/figcaption><\/figure>\n

    Calibration Procedure: <\/span>\u200b<\/p>\n

      \n
    • The hot plate and fan were turned on first to allow the system to come to steady state. The wind sensors were used to adjust the flow valves at the bottom of the columns to ensure that they were all receiving an approximately equal flow rate of about 3 m\/s, corresponding to the flow rates mentioned above. This procedure took approximately 30 minutes.<\/li>\n
    • There were no beds present in any of the columns at this time.<\/li>\n
    • Ammonia was introduced to the columns via the evaporation system. These amounts contained different amounts of a 13% NH4OH solution designed to deliver NH3 concentrations ranging from 0 ppm to 200 ppm in 20 ppm increments, each diluted to give the same volume of overall solution to match the setting on the peristaltic pipe.<\/li>\n
    • The columns were allowed to reach breakthrough and then once again achieve steady-state.<\/li>\n
    • Throughout the course of this procedure, the ammonia sensors put out voltage data that was recorded by LabVIEW.<\/li>\n
    • The calibration plots are shown in Figure 5, generated using equation 2.<\/li>\n
    • It should be noted that Sensor 2 did not provide a usable equation translating voltages to ppm values, so the remainder of this analysis will primarily be carried out from the standpoint of voltage outputs.<\/li>\n<\/ul>\n
      \"\"
      Equation 2: Ammonia concentration at sensor “n” calculated from the its voltage outputs before and during ammonia exposure.<\/figcaption><\/figure>\n
      \"\"
      Figure 7. Change of internal resistance caused by differing amounts of ammonia exposure. The relationship is linear on a log-log plot.<\/figcaption><\/figure>\n

      Experimental Procedure<\/p>\n

        \n
      • The beds were loaded into the columns following the design specifications previously discussed.<\/li>\n
      • The calibration procedure previously mentioned was run, but with the following two differences:<\/li>\n
      • One. When the wind sensors were no longer working (see Results and Discussion), pressure difference across the beds to ensure that the columns all had about the same flow rate.<\/li>\n
      • Two. The inlet concentration of ammonia was kept at 100 ppm of ammonia rather than the varied intervals mentioned above.<\/li>\n<\/ul>\n

        Results and Discussion<\/span><\/p>\n

        \"\"
        Figure 8: voltage output of all 4 outlet ammonia sensors vs time for the first experiment trial on 04\/15\/2024.<\/figcaption><\/figure>\n
        \"\"
        Figure 9. Total mass, in grams, of ammonia adsorbed in each column. Data is compiled over three separate trials.<\/figcaption><\/figure>\n
        \"\"
        Table 1: One-way analysis of variance (ANOVA) results for ammonia adsorption. High P-value and low F-statistic indicate no statistical differences between bed performance.\u200b<\/figcaption><\/figure>\n

        Results of Initial Trials<\/span>\u200b<\/p>\n

          \n
        • Breakthrough occurred first in Bed 1, then 2 & 3 followed by 4 in Trial 1\u00a0<\/span>(Figure 6), which supported our hypothesis that the manure-inoculated\u00a0<\/span>column had the highest\u00a0capacity of ammonia at about 3.95 gNH3 (Figure 7).<\/span>\u200b<\/li>\n
        • Bed 4 was observed to have become dry over the course of the experiment,\u00a0<\/span>so it\u00a0is possible that microbe activity decreased with dryness.<\/span>\u200b<\/li>\n
        • Figure 7 illustrates the varied\u00a0performance of each packing material across\u00a0<\/span>all trials, where Bed 4 is the best performing\u00a0in our first trial, less than but\u00a0<\/span>comparable to Bed 3 in the second trial, and the worst\u00a0in the last trial. The\u00a0<\/span>second trial showed Bed 1 to\u00a0be the worst-performing out of all the beds.\u00a0<\/span>\u200b<\/li>\n
        • All bed materials had about the same ammonia capacity, and Bed 4 only\u00a0<\/span>slightly outperformed the rest.\u00a0Thus, the results of our experiment were\u00a0<\/span>somewhat inconclusive.<\/span>\u200b<\/li>\n<\/ul>\n
          \"\"
          Figure 9: Percentage of ammonia reduced by each bed over time (0-6000 seconds).<\/figcaption><\/figure>\n

          Conclusions<\/span><\/p>\n

          While the inoculated column performed better than the others overall and <\/span><\/span>biochar improved performance, further research is needed to verify\u00a0this\u00a0<\/span><\/span>finding. Because the beds all saturate within a few hours, our sponsor will\u00a0<\/span><\/span>likely need to incorporate more robust filtration tactics to extend the filter\u00a0<\/span><\/span>lifetime and achieve the desired filtration results. Alternative methods such as\u00a0<\/span><\/span>water scrubbing systems are commonly used to remove ammonia from the air\u00a0<\/span><\/span>due to ammonia’s high affinity for water. Adding a water bath and overhead\u00a0<\/span><\/span>sprinkler system to the air stream of the current shipping container system\u00a0<\/span><\/span>follows this approach. Municipal wastewater treatments utilize large\u00a0microbe-<\/span><\/span>holding\u00a0water tanks, and attempting to replicate this is another feasible path\u00a0<\/span><\/span>forward .\u00a0This takes a similar approach to that of the inoculated bed but would\u00a0<\/span><\/span>potentially give nitrogen-processing bacteria a longer window of time to\u00a0<\/span><\/span>process ammonia than gas flow through a solid-packed bed.\u00a0<\/span><\/span><\/p>\n

          Acknowledgements<\/u><\/p>\n

          Team Censorship would like to acknowledge the following:\u00a0<\/span><\/p>\n

            \n
          • Our advisor Professor Kelley, Professor Lawton, Professor Juba, and our sponsor Hal Kreher, for their insight <\/span>and guidance over the course of this project;\u00a0<\/span>\u200b<\/li>\n
          • Clair Cunningham, Jeff Leffler, and Mason <\/span>Garlatti<\/span>, for their help in constructing our experimental apparatus;<\/span>\u200b<\/li>\n
          • The Hajim School\u00a0Department of Chemical Engineering, for providing the\u00a0<\/span>resources and funds to make this\u00a0<\/span>project possible<\/span>.\u00a0\u00a0<\/span>\u200b<\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"

            Ammonia Biofilter Optimization for Chicken Manure Composting Authors: Geoffrey Doyle, Jason Maher, and Aidan Shea Advisor: Professor Kelley \u200b Department: Chemical Engineering Sponsor: Hal Kreher, Kreher Farms Introduction Kreher Farms\u00a0is…<\/p>\n","protected":false},"author":6242,"featured_media":183022,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_coblocks_attr":"","_coblocks_dimensions":"","_coblocks_responsive_height":"","_coblocks_accordion_ie_support":"","_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[4442,76,2956,3086],"tags":[],"coauthors":[8612],"class_list":["post-153982","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-archive","category-che-archive","category-energy-environmental-archive","category-process-engineering-archive"],"acf":[],"yoast_head":"\nAmmonia Biofilter Optimization for Chicken Manure Composting\u200b - Senior Design Day<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/ammonia-biofilter-optimization-for-chicken-manure-composting\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Ammonia Biofilter Optimization for Chicken Manure Composting\u200b - Senior Design Day\" \/>\n<meta property=\"og:description\" content=\"Ammonia Biofilter Optimization for Chicken Manure Composting Authors: Geoffrey Doyle, Jason Maher, and Aidan Shea Advisor: Professor Kelley \u200b Department: Chemical Engineering Sponsor: Hal Kreher, Kreher Farms Introduction Kreher Farms\u00a0is…\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/ammonia-biofilter-optimization-for-chicken-manure-composting\/\" \/>\n<meta property=\"og:site_name\" content=\"Senior Design Day\" \/>\n<meta property=\"article:published_time\" content=\"2024-05-03T14:59:37+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2025-05-02T18:50:03+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.hajim.rochester.edu\/senior-design-day\/wp-content\/uploads\/2024\/05\/Screenshot-2024-05-01-135308-300x209-1.png\" \/>\n\t<meta property=\"og:image:width\" content=\"300\" \/>\n\t<meta property=\"og:image:height\" content=\"209\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/png\" \/>\n<meta name=\"author\" content=\"admin\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"admin\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"11 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/ammonia-biofilter-optimization-for-chicken-manure-composting\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/ammonia-biofilter-optimization-for-chicken-manure-composting\\\/\"},\"author\":{\"name\":\"admin\",\"@id\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/#\\\/schema\\\/person\\\/351018fbcf84ed8cac6d8072ba5b347c\"},\"headline\":\"Ammonia Biofilter Optimization for Chicken Manure Composting\u200b\",\"datePublished\":\"2024-05-03T14:59:37+00:00\",\"dateModified\":\"2025-05-02T18:50:03+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/ammonia-biofilter-optimization-for-chicken-manure-composting\\\/\"},\"wordCount\":1624,\"image\":{\"@id\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/ammonia-biofilter-optimization-for-chicken-manure-composting\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.hajim.rochester.edu\\\/senior-design-day\\\/wp-content\\\/uploads\\\/2024\\\/05\\\/Screenshot-2024-05-01-135308-300x209-1.png\",\"articleSection\":[\"3. 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