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e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327



                                                  available at www.sciencedirect.com




                                       journal homepage: www.elsevier.com/locate/ecoleng



An economic assessment of algal turf scrubber technology
for treatment of dairy manure effluent

C. Pizarro a , W. Mulbry b,∗ , D. Blersch a , P. Kangas a
aBiological Resources Engineering Department, University of Maryland, College Park, MD 20742, USA
bEnvironmental Management and Byproducts Utilization Lab, USDA/ARS, Building 306, Room 109, BARC East, 10,300 Baltimore
Avenue, Beltsville, MD 20705, USA



a r t i c l e          i n f o                    a b s t r a c t

Article history:                                  Controlling the input of nitrogen (N) and phosphorus (P) from dairies and other livestock
Received 18 March 2005                            operations into the surrounding air- and water-sheds poses both technical and economic
Received in revised form                          challenges to the agricultural community. The purpose of this paper is to assess the eco-
30 November 2005                                  nomics of algal turf scrubber treatment technology at the farm-scale for a hypothetical
Accepted 7 December 2005                          1000-cow dairy. Costs were developed for farms with and without anaerobic pretreatment.
                                                  The majority of capital costs were due to land preparation, installation of liner material,
                                                  and engineering fees. The majority of operational costs were due to energy requirements
Keywords:                                         for biomass drying, pumping water, and repayment of capital investment. On farms using
Algal turf scrubber                               anaerobic pretreatment, waste heat from burning of biogas could be used to offset the energy
Dairy manure                                      requirements of biomass drying. In addition, biogas combustion exhaust gas could then be
Phytoremediation                                  recycled back to the algal system to supply dissolved inorganic carbon for optimal algal
Algae                                             production and pH control. Under the best case (algal system coupled with anaerobic diges-
Nitrogen                                          tion pretreatment), the yearly operational costs per cow, per kg N, per kg P, and per kg of
Phosphorus                                        dried biomass were $454, $6.20, $31.10, and $0.70, respectively. Without anaerobic digestion
Organic fertilizer                                pretreatment, the yearly operational costs were 36% higher, amounting to $631 per cow,
                                                  $8.70 per kg N, $43.20 per kg P, and $0.97 per kg of dried biomass. For perspective, a recent
                                                  survey of 36 Maryland dairy farms found long-term annual profits of about $500 per cow.
                                                  As no market currently exists for manure grown algal biomass, our cost analysis does not
                                                  include any value of the biomass generated during manure treatment. In addition, there
                                                  are a variety of potential uses for the algal biomass from manure treatment that could
                                                  defray treatment costs. Future opportunities for dairies to participate in nutrient trading
                                                  approaches to watershed nutrient management may also become important.
                                                                                                                         Published by Elsevier B.V.




1.           Introduction                                                          1993; Kaiser, 2001; Van Horn et al., 1994). During storage and
                                                                                   land application of manure effluents, large amounts of N
Controlling the input of nitrogen (N) and phosphorus (P)                           are lost to the atmosphere due to volatilization of ammo-
from dairies and other livestock operations into the sur-                          nia. Recent estimates suggest that animal waste contributes
rounding air- and water-sheds poses both technical and eco-                        18% of the N and 25% of the P inputs to the Chesapeake
nomic challenges to the agricultural community (Adey et al.,                       Bay (Chesapeake Bay Foundation, 2004) where water qual-



    ∗
        Corresponding author. Tel.: +1 301 504 6417; fax: +1 301 504 8162.
        E-mail address: mulbryw@ba.ars.usda.gov (W. Mulbry).
0925-8574/$ – see front matter. Published by Elsevier B.V.
doi:10.1016/j.ecoleng.2005.12.009
322                                        e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327



ity has declined dramatically due to eutrophication (Horton                   ters (Adey et al., 1996). The system consists of an attached algal
and Eichbaum, 1991). Ecologically sound manure manage-                        community growing on screens in a trough through which
ment on farms is vital to minimize losses of valuable plant                   polluted water flows. The algal community is a high diversity
nutrients and to prevent nutrient contamination of the sur-                   system with 30 or more species of algae, along with associated
rounding watershed. The challenge for ecological engineering                  microbes and micro-invertebrates. When operated at neutral
is to develop technologies that can economically treat manure                 pH values, this living community provides most of the water
as a waste source and, ideally, transform it into a useful                    treatment by uptake of inorganic compounds in primary pro-
byproduct.                                                                    duction and breakdown of organic compounds in community
    An alternative to land spreading of manure is to grow crops               respiration (Adey and Loveland, 1998).
of algae on the N and P present in the manure and convert                        This system is modeled on the algal turf community found
manure N and P into algal biomass. Most efforts in using                      on coral reefs, which have some of the highest recorded
algal production for wastewater treatment have been focused                   metabolisms of any ecosystem (Adey and Goertemiller, 1987).
on treatment of municipal waste effluents using suspended                      Metabolism of the algal turf scrubber is controlled by manip-
microalgae (Benemann and Oswald, 1996; Green et al., 1995).                   ulating water depth and flow rates, use of natural or artificial
Wastewater treatment using attached algae (periphyton) has                    light sources, control of herbivores and frequency of harvest.
also been reported and has potential advantages in how the                    All of these factors can be adjusted to maximize metabolism
algal biomass is harvested and dried (Hoffman, 1998). One                     and, thus, to maximize water treatment capacity. Harvest-
technology using periphyton, termed algal turf scrubbers (ATS)                ing is particularly important since this action rejuvenates the
(Adey and Hackney, 1989; Adey and Loveland, 1998), is rela-                   community and leads to high growth rates. In fact, biomass
tively simple in design and yields an algal biomass that can                  production rates of algal turf scrubbers are among the high-
be easily harvested on adapted farm-scale equipment. Previ-                   est of any recorded values for constructed ecosystems (Adey
ous work in this laboratory has demonstrated the use of ATS                   and Loveland, 1998). Many pollutants are taken up in algal
periphyton to remove N and P from dairy manure effluents                       biomass and are removed from the system through harvest
(Kebede-Westhead et al., 2003; Wilkie and Mulbry, 2002) as                    (Adey et al., 1996). If these pollutants are not toxic, the har-
well as the use of the resulting biomass as an organic fertil-                vested material can be processed into a useful byproduct such
izer (Kebede-Westhead et al., 2004; Mulbry et al., 2005). The                 as a fertilizer or feed. If the pollutants are toxic, the harvested
purpose of this paper is to assess the economics of ATS treat-                material must be disposed of, usually through land filling or
ment technology at the farm-scale for a hypothetical 1000-cow                 incineration.
dairy.
                                                                              3.1.1.      Operating parameters
                                                                              The proposed treatment system (Figs. 1 and 2) is designed
2.      Treatment goals
                                                                              on the basis of operations at the Dairy Research Unit of the
                                                                              USDA/ARS facility in Beltsville, MD (USA) (Wilkie and Mulbry,
Within the economics and technology appropriate to farming
                                                                              2002). In this confined animal operation, manure, urine, saw-
systems, manure treatment systems should:
                                                                              dust (used as bedding material) and variable amounts of water
                                                                              are mechanically scraped from the barns into an underground
(1) Achieve >80% reduction of atmospheric emissions                           sump on a continuous basis. This mixture (about 12% total
    (ammonia-N, methane, odor compounds) from manure.                         solids (TS)) is pumped to a screw press separator where the
(2) Concentrate and stabilize nutrients from manure effluents                  majority of solids are removed, and the manure effluent (about
    so that the nutrients can be efficiently recycled on-farm or               5% TS) is fed at intervals to an anaerobic digestor for biogas
    exported off-farm.                                                        production. The digested effluent is subsequently stored in
(3) Operate year-round so as to greatly reduce or eliminate                   an open lagoon prior to land application in the spring and fall.
    storage of manure effluent in lagoons.                                     The proposed system assumes that one-third of the manure
(4) Accommodate a wide range of dairy effluents with variable                  N and P are lost due to ammonia volatilization in the barns
    nutrient and solids content.                                              and/or removed with manure solids during solids separation
(5) Achieve >80% recovery of manure N and P at an overall                     prior to treatment of the manure effluent (Fig. 1) (Chesapeake
    cost of <$5 per pound N ($11 per kg N).                                   Bay Foundation, 2004). Manure solids are composted prior to
                                                                              land application on- or off-farm. The remaining two thirds
                                                                              of the manure N and P (200 g TN and 40 g TP day−1 cow−1 or
3.      Description of the proposed system
                                                                              73,000 kg TN and 14,600 kg TP year−1 for 1000 dairy cows) are
                                                                              pre-treated by anaerobic digestion followed by algal treatment
3.1.    Algal turf scrubbers                                                  using an 11 ha system. In Maryland the algal system could be
                                                                              operated for approximately 9 months of the year with reduced
Algal turf scrubbers are a new technology for treating waste-                 productivity in the fall and winter months coinciding with
water that utilize multi-species assemblages dominated by                     reduced light levels. Under this scenario, all digested manure
benthic, filamentous algal taxa (Adey and Loveland, 1998). This                effluent is treated immediately except for material that is col-
technology was developed by Dr. Walter Adey of the Smithso-                   lected and stored during the three coldest months (approxi-
nian Institution and has been shown to be effective for improv-               mately December–February). This growing season would obvi-
ing the water quality of agricultural runoff (Adey et al., 1993),             ously vary with geographic location and affects the size of the
domestic sewage (Craggs et al., 1996), and industrial wastewa-                treatment area.
e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327                323




Fig. 1 – Schematic diagram of nutrient flow in the proposed treatment system. Manure from dairy cows in free-stall barns is
mechanically scraped (or flushed with water) and the resultant manure slurry is subjected to a solids separation step prior
to treatment of the solids by composting and treatment of the effluent by anaerobic digestion and algal scrubbing. Values
for input N and P, milk N and P were adapted from Van Horn et al. (1994, 1996). Biomass from the algal scrubbers is either
recycled back into farm operations (as a feed supplement or fertilizer) or exported from the farm.




Fig. 2 – Schematic diagram of 1 ha ATS unit with associated equipment and water reservoir. Manure effluent is added
continuously to the equalization reservoir. Algal biomass is harvested weekly, removed from ATS effluent using a
mechanical rake, dewatered with a screw press, and dried using a belt drier. A 1000-animal farm-scale system would be
composed of eleven 1 ha ATS units that would share reservoirs and the harvesting, dewatering, and drying equipment.
324                                            e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327



3.1.2.    Manure characterization                                                 ple mechanical dewatering yields biomass containing 20%
The absolute and relative concentrations of different compo-                      total solids. Algal biomass would be stabilized by drying
nents in dairy manure are dependent on the breed of animal,                       to 90% solids (10% moisture) and would contain 40% C,
amount and composition of feed as well as water use in the                        7.5% N, 1.5% P and an ash content of about 15%. We esti-
barns. Van Horn et al. (1994) summarized manure composi-                          mate an average biomass productivity rate of 22 g m−2 day−1
tion values from a variety of literature sources and we used                      (at 10% moisture content) (Kebede-Westhead et al., 2003).
their value of 300 g TN excreted per cow per day. There is con-                   This value corresponds to field-scale productivity rates of
siderable variation in estimates of the proportions of manure                     220 kg ha−1 day−1 and 2420 kg day−1 (653,400 kg per 270-day
N and P that are removed during solids separation. At the                         operating year) for an 11 ha treatment system for 1000
USDA facility, the solids content of the raw and separated efflu-                  cows.
ents average 12% and 5%, respectively. For the purposes of
this assessment, we assume that the solids separated manure                       3.1.5. Biogas and energy production from anaerobic
effluent contains 200 g of TN and 40 g TP per day per cow                          digestion of manure
(equivalent to 73 kg TN and 14.6 kg TP per year per cow).                         Values for biogas and energy production from anaerobic
                                                                                  digestion of dairy manure have been estimated previously
3.1.3.    Manure loading rates                                                    (Van Horn et al., 1996, 1994). Assuming each cow produces
Results from laboratory scale algal scrubbers using diluted                       5.73 kg of manure volatile solids (VS) day−1 , and anaero-
anaerobically digested dairy manure show maximum                                  bic digestion yields approximately 350 L of biogas kg−1 VS,
productivity (roughly 20 g D.W. m−2 day−1 ) at loading of                         biogas production is roughly 2000 L day−1 cow−1 . Assuming
2.5 g TN m−2 day−1 (Kebede-Westhead et al., 2003). We used                        biogas is composed of 60% methane with an energy con-
this value for the average manure loading rate in the ATS.                        tent of 8.90 kcal L−1 , total energy production is estimated
This corresponds to an approximate P loading rate of                              at 10.7 Mcal cow−1 day−1 (Van Horn et al., 1994). For a dairy
0.5 g TP m−2 day−1 . For this assessment, we assume 9 months                      farm with 1000 cows, the total energy production would be
(270 days) of algal production per year. Using a yearly average                   10,700 Mcal day−1 or 3.9 × 106 Mcal year−1 .
of 2.5 g TN m−2 loaded on ATS per day, 270 days per year yields
N and P loading rates of 0.675 kg TN and 0.135 kg TP m−2 year−1
(6750 kg TN and 1350 kg TP ha−1 year−1 ). Assuming that solids                    3.1.6.      Energy requirements for biomass drying
separated manure effluent from each cow contains approxi-                          Harvested algal biomass (4000 kg per ha) would contain
mately 73 kg TN and 14.6 kg TP per year (shown above), then                       roughly 5% solids. After dewatering (3000 kg water removed
each hectare of ATS raceways will treat the yearly solids                         from 4000 kg harvested biomass) the algal biomass would con-
separated manure effluent from about 92 cows.                                      tain 20% solids (1000 kg per ha) and could be subsequently
                                                                                  stabilized by drying to 90% solids (220 kg of dried product
3.1.4.    Algal biomass characteristics and productivity                          per ha). The calculated energy requirement for drying 780 kg
At a loading rate of 2.5 g TN m−2 day−1 , harvested ATS                           water from 1000 kg of dewatered biomass (using an energy
biomass contains about 5% total solids at harvest and sim-                        consumption of 1.2 Mcal kg−1 H2 O) is 932 Mcal ha−1 day−1 .



 Table 1 – Capital cost estimates for manure effluent treatment system (for 1000 cows)
                                                                 No pre-treatment ($)                        Pre-treatment with anaerobic digestor ($)

 Site preparation, grading, compaction ($34,000 ha−1 )a                 374,000                                                374,000
 HDPE liner and installation costs ($33,000 ha−1 )a                     363,000                                                363,000
 Pumpb                                                                  93,000                                                 93,000
 Carbon dioxide sumps, diffusers ($4000 ha−1 )c                         44,000                                                 44,000
 Roads, drainage ($7000 ha−1 )a                                         77,000                                                 77,000
 Electrical supply and distribution ($3000 ha−1 )a                      33,000                                                 33,000
 Instrumentation and machinery ($500 ha−1 )c                            5,500                                                   5,500
 Land cost ($3500 ha−1 )a                                               38,500                                                 38,500
 ATS Screen ($6090 ha−1 )a                                              67,000                                                 67,000
 Algal harvestera                                                       85,000                                                 85,000
 Mechanical dewatering to 20% solidsd                                   35,000                                                 35,000
 Algal driere                                                           135,000                                                135,000
 Subtotal                                                               1,350,000                                               1,350,000
 Engineering and contingencies (15% of subtotal cost)c                  202,500                                                202,500
 Total direct capital                                                   1,552,600                                               1,552,600
 Working capital (25% of net operating cost)c                           123,000                                                81,900

 Total capital investment                                               1,675,600                                               1,634,500

 a
     Values provided by Hydromentia, Inc. based on a proposed 11 ha 189,000 m3 day−1 treatment facility for agricultural wastewater.
 b
     Value based on a single 189,000 m3 day−1 pump for the 11 ha treatment area.
 c
     Benemann and Oswald, 1996.
 d
     FAN screw press (www.fsaconsulting.net/pdfs).
 e
     Belt drier with evaporation capacity of 9000 kg water day−1 to yield biomass with 10% moisture.
e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327                                        325


 Table 2 – Annual operational cost estimates for manure effluent treatment system
                                                         No pre-treatment ($)                                 Pre-treatment with anaerobic digestor ($)

 Power for mixinga                                                  165,500                                                     165,500
 Power for harvesting and dewateringb                                13,200                                                      13,200
 Power for dryingc                                                  173,300                                                       0
 Labor and overheadsd                                                62,400                                                      62,400
 Maintenance, taxes, insurancee                                      77,600                                                      77,600
 Total net operating cost                                           492,000                                                     327,500
 Capital chargef                                                    139,100                                                     135,700
 Total annual costs                                                 631,100                                                     454,200

 Cost per cow if biomass is driedg                                  631                                                         454
 Cost per cow if biomass is not driedh                              454                                                         454
 Cost per kg N if biomass is driedi                                   8.70                                                        6.20
 Cost per kg P if biomass is driedj                                  43.20                                                       31.10
 Cost per kg N if biomass is not driedk                               6.20                                                        6.20
 Cost per kg P if biomass is not driedl                              31.10                                                       31.10
 Cost per kg of dried algaem                                          0.97                                                        0.70

 a
   Electricity cost for 189,000 m3 day−1 pump for 270 days (assuming $0.06 per kWh).
 b
   Electricity cost for mechanical rake harvester and FAN screw press.
 c
   Electricity cost to remove 7000 kg day−1 water from 11,000 kg day−1 wet biomass for 270 days assuming energy consumption of 1.389 kWh kg−1
   H2 O at 46% thermal efficiency.
 d
   Estimate for two full-time equipment operators at $15 h−1 .
 e
   Calculated as 5% of total direct capital cost Benemann and Oswald, 1996.
 f
   Calculated as 8.3% of total capital investment.
 g
   Total annual cost divided by 1000 cows.
 h
   Total annual cost minus the cost of power for drying divided by 1000 cows.
 i
   Total annual cost divided by 73,000 kg N from 1000 cows.
 j
   Total annual cost divided by 14,600 kg P from 1000 cows.
 k
   Total annual cost minus the cost of power for drying divided by 73,000 kg N.
 l
   Total annual cost minus the cost of power for drying divided by 14,600 kg P.
 m
   Based on 653,400 kg algal biomass produced during 270 days.


For an 11 ha treatment area and 270 days of operation per                       of the capital investment (the “capital charge”). The capital
year, the corresponding total energy requirement would be                       charge (calculated here as the annual charge required to pay
2.8 × 106 Mcal year−1 .                                                         off the facility within a 20 year period at 5% interest) accounts
                                                                                for 21–28% of total annual costs.

4.      Results
                                                                                5.          Discussion
Estimated capital and annual operational costs for the pro-
posed treatment system are shown in Tables 1 and 2. Costs                       5.1.    Comparison with alternative treatment
are shown for a system without anaerobic pretreatment and                       systems
for a system that includes anaerobic pretreatment. The major-
ity of capital costs were due to land preparation, installation                 Other ecologically engineered alternatives to the algal turf
of liner material, and engineering fees (Table 1). The major-                   scrubber exist for treating dairy and other types of ani-
ity of operational costs were due to energy requirements for                    mal manure. Constructed wetlands have been tested exten-
biomass drying, pumping water, and repayment of capital                         sively for this purpose (Cronk, 1996; Hunt and Poach, 2001;
investment (Table 2). On farms using anaerobic pretreatment,                    Schaafsma et al., 2000). Wetland cells are usually positioned
waste heat from burning biogas could be used to offset the                      after a lagoon or solids separator and they function primar-
energy requirements of biomass drying (Table 2, column 2). In                   ily to reduce BOD and nitrogen. Although relatively short-
addition, biogas combustion exhaust gas could then be recy-                     term studies (1–3 years duration) have demonstrated that con-
cled back to the algal system to supply dissolved inorganic                     structed wetlands can effectively treat manure wastewater,
carbon for optimal algal production and pH control (the costs                   their long-term capacity for phosphorus treatment is limited
of such a carbon recycling system are not included in this anal-                (Poach et al., 2003).
ysis) (Benemann and Oswald, 1996). Under the best case (algal                       High-rate algal ponds also have been utilized for treat-
system coupled with anaerobic digestion pretreatment), the                      ing manure effluent (Costa et al., 2000; Craggs et al., 2003;
yearly operational costs per cow, per kg of N, per kg of P, and per             Dugan et al., 1972; Goh, 1986; Olguin, 2003). In this technol-
kg of dried biomass were $454, $6.20, $31.10, and $0.70, respec-                ogy suspended phytoplankton and bacteria in slow moving,
tively. Clearly, these calculated values are dependent on the                   shallow raceways are used to metabolize the manure pol-
many parameters outlined in the assessment. The operational                     lutants. Advanced integrated high rate ponds have evolved
costs are particularly sensitive to the costs for repayment                     from passive, facultative ponds and they are used for treat-
326                                        e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327



ing domestic sewage (Green et al., 1996, 1995; Nurdogan and                   municipal wastewater treatment facilities in this case) to
Oswald, 1995). Given their demonstrated performance in treat-                 obtain pollution reduction credits from sources (dairy farm-
ing other types of wastewater, high rate pond technology has                  ers in this case) that can reduce their nutrient contribution to
significant potential for treating dairy manure effluent.                       the watershed at a lower cost (Greenhalgh and Sauer, 2003).
    Finally, Hillman and Culley (1978) described a duckweed
(Lemna sp.) system for treating dairy wastewater (Hillman and                 6.1.        Nitrogen credit
Culley, 1978). A hypothetical design was proposed for a 100-
cow farm operation, utilizing a sequence of lagoons, but no                   A range of N credit values have been cited in different stud-
empirical performance data was given.                                         ies and models relevant to the Chesapeake Bay watershed.
    Thus, alternative treatment systems have been proposed                    Greenhalgh and Sauer used relatively conservative values of
and tested. Unfortunately, however, very few published stud-                  $2 and $5 per lb N ($4.4 and $11 per kg N) among the different
ies report economic costs for treatment systems. Hammer et                    options tested in their model on the economic and environ-
al. (1993) reported some data for a swine wastewater con-                     mental impact of different policy options to reduce agricul-
structed wetland in Alabama but only capital costs were given.                tural nutrient inputs into the Mississippi River and Gulf of
The total cost for about 6000 m2 of constructed wetland was                   Mexico. Values for potential nutrient trading credits may also
$12,800. Interestingly, an old study projected costs of $70 per               be developed from incremental cost estimates for upgrading
ton of dried algae for a high-rate pond system (Martin and                    municipal wastewater treatment (MWTP) in the Chesapeake
Madewell, 1971) to treat waste from poultry, swine, and cat-                  Bay watershed (Chesapeake Bay Program, 2002). Values ranged
tle operations. However, drying costs were not included and                   from $8 per lb N ($17.60 per kg N) for annualized incremental
an updated analysis is needed to assess the viability of this                 MWTP tiers 1 and 2 targets (to achieve effluent discharge levels
alternative.                                                                  of 8 ppm) to $14 per lb ($30.80 per kg N) for annualized MWTP
                                                                              tier 3 costs (to achieve effluent discharge levels of 5 ppm). For
5.2.    Byproduct value of ATS algae                                          dried algal biomass containing 7.5% N, N credit values of $2,
                                                                              $5, $8, and $14 per lb N correspond to $0.33, $0.82, $1.32, and
As no market currently exists for manure-grown algal                          $2.31 per kg, respectively, for values of dried algal biomass. All
biomass, our cost analysis does not include any value for                     but the lowest value would cover the projected cost of manure
the biomass generated during manure treatment. However,                       treatment using algal production.
there are a variety of potential uses for the algal biomass from
manure treatment. Fresh dewatered biomass could potentially                   6.2.        Phosphorus credit
be mixed in with animal feed (and substituted on a protein
basis for soybeans) (Wilkie and Mulbry, 2002). Although this                  Corresponding values for P treatment credits are $5–7 per lb P
use for the biomass would avoid drying and transportation                     ($11–15 per kg P) (Greenhalgh and Sauer, 2003). The value of $5
costs, such use would be relatively low value and the poten-                  per lb P was reported to be equivalent to MWTP cost for achiev-
tial exists for disease transmission. Dewatered biomass could                 ing 1 ppm TP and $7 per lb P was reported to be equivalent
also be bulked with other agricultural wastes and composted.                  to MWTP cost for achieving “<1 ppm” TP. Although the values
This use would be of little direct value but would also avoid                 from potential upgrade costs wastewater treatment to achieve
drying and transportation costs.                                              improved P discharge limits are somewhat difficult to separate
    Although more expensive to produce (Table 2), dried algal                 out from costs of improved N treatment, the Chesapeake Bay
biomass is considerably easier to utilize because the nutrients               report separates out an incremental cost for TP reduction of
are concentrated and stabilized, pathogens are eliminated,                    about $1 per kg P (Chesapeake Bay Foundation, 2004). How-
and it is easily ground for different formulations. Recent stud-              ever, nutrient trading credits for P reduction would be about
ies focused on use of the dried biomass as an organic fertilizer              seven-fold less than N credits since the algal biomass contains
demonstrated that it was equivalent to a commercial organic                   only 1% P. A credit of $11 per kg P would be equivalent to only
fertilizer with respect to plant mass and nutrient content                    $0.11 per kg dried algae and would represent roughly 10% of
(Mulbry et al., 2005). Although the composition of the dried                  treatment costs.
biomass varies with loading rate, heavy metal content is well
below regulatory limits (Kebede-Westhead et al., 2004). The
home consumer market is the most attractive with respect to                   7.          Conclusion
price with retail prices of $2–3 kg−1 for comparable organic fer-
tilizers. However, the pricing at which the dried algal biomass               For perspective, the cost of manure treatment must be com-
could successfully penetrate this market is unknown.                          pared with the profits from dairy operations. Johnson and
                                                                              coworkers surveyed 36 dairy farm owners in Maryland for the
                                                                              years 1997–2003 and found long-term annual profits of about
6.      Potential for nutrient trading credits                                $500 per cow (Johnson et al., 2005). Based on this relative value,
                                                                              costs of treatment projected in this study for an ATS system
Beyond any value that the algal biomass may have as a fertil-                 are very high and would consume most profit ($454 per cow for
izer, feed supplement, or chemical feedstock, there are other                 algal system coupled with anaerobic digestion pre-treatment)
potential sources of revenue to offset the costs of manure                    or exceed profit ($631 per cow for algal system without pre-
treatment. Nutrient trading is a market-based approach that                   treatment). However, the economic balance becomes more
allows pollution sources with high treatment costs (such as                   favorable if values from algae as a byproduct (e.g. fertilizer sale)
ecological engineering        26   ( 2 0 0 6 ) 321–327                                      327


and nutrient trading credits can be realized. In addition, there       Goh, A., 1986. Production of microalgae using pig waste as a
are many opportunities for agricultural grants or cost-sharing             substrate. In: Barclay, W.R., McIntosh, R.P. (Eds.), Algal
at the state and national levels that could defray capital and/or          Biomass Technologies. Cramer, Berlin, pp. 235–244.
                                                                       Green, F.B., Bernstone, L.S., Lundquist, T.J., Oswald, W.J., 1996.
operational costs. The USDA’s Environmental Quality Incen-
                                                                           Advanced integrated wastewater pond systems for nitrogen
tives Program (which provides up to 75% cost share of capital              removal. Water Sci. Technol. 33, 207–217.
costs to a maximum of $450,000 per 5 year farm bill cycle)             Green, F.B., Lundquist, T.J., Oswald, W.J., 1995. Energetics of
would be important in this regard. These kinds of economic                 advanced integrated wastewater pond systems. Water Sci.
considerations must be dealt with if dairy wastewater treat-               Technol. 31, 9–20.
ment is to be mandated in the future.                                  Greenhalgh, S., Sauer, A., 2003. Awakening the ’Dead Zone’: An
                                                                           Investment for Agriculture, Water Quality, and Climate
                                                                           Change. World Resources Institute, Washington, DC, p. 24.
                                                                       Hammer, D.A., Pullin, B.P., McCaskey, T.A., Eason, J., Payne,
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Presentación Algas

  • 1. e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 available at www.sciencedirect.com journal homepage: www.elsevier.com/locate/ecoleng An economic assessment of algal turf scrubber technology for treatment of dairy manure effluent C. Pizarro a , W. Mulbry b,∗ , D. Blersch a , P. Kangas a aBiological Resources Engineering Department, University of Maryland, College Park, MD 20742, USA bEnvironmental Management and Byproducts Utilization Lab, USDA/ARS, Building 306, Room 109, BARC East, 10,300 Baltimore Avenue, Beltsville, MD 20705, USA a r t i c l e i n f o a b s t r a c t Article history: Controlling the input of nitrogen (N) and phosphorus (P) from dairies and other livestock Received 18 March 2005 operations into the surrounding air- and water-sheds poses both technical and economic Received in revised form challenges to the agricultural community. The purpose of this paper is to assess the eco- 30 November 2005 nomics of algal turf scrubber treatment technology at the farm-scale for a hypothetical Accepted 7 December 2005 1000-cow dairy. Costs were developed for farms with and without anaerobic pretreatment. The majority of capital costs were due to land preparation, installation of liner material, and engineering fees. The majority of operational costs were due to energy requirements Keywords: for biomass drying, pumping water, and repayment of capital investment. On farms using Algal turf scrubber anaerobic pretreatment, waste heat from burning of biogas could be used to offset the energy Dairy manure requirements of biomass drying. In addition, biogas combustion exhaust gas could then be Phytoremediation recycled back to the algal system to supply dissolved inorganic carbon for optimal algal Algae production and pH control. Under the best case (algal system coupled with anaerobic diges- Nitrogen tion pretreatment), the yearly operational costs per cow, per kg N, per kg P, and per kg of Phosphorus dried biomass were $454, $6.20, $31.10, and $0.70, respectively. Without anaerobic digestion Organic fertilizer pretreatment, the yearly operational costs were 36% higher, amounting to $631 per cow, $8.70 per kg N, $43.20 per kg P, and $0.97 per kg of dried biomass. For perspective, a recent survey of 36 Maryland dairy farms found long-term annual profits of about $500 per cow. As no market currently exists for manure grown algal biomass, our cost analysis does not include any value of the biomass generated during manure treatment. In addition, there are a variety of potential uses for the algal biomass from manure treatment that could defray treatment costs. Future opportunities for dairies to participate in nutrient trading approaches to watershed nutrient management may also become important. Published by Elsevier B.V. 1. Introduction 1993; Kaiser, 2001; Van Horn et al., 1994). During storage and land application of manure effluents, large amounts of N Controlling the input of nitrogen (N) and phosphorus (P) are lost to the atmosphere due to volatilization of ammo- from dairies and other livestock operations into the sur- nia. Recent estimates suggest that animal waste contributes rounding air- and water-sheds poses both technical and eco- 18% of the N and 25% of the P inputs to the Chesapeake nomic challenges to the agricultural community (Adey et al., Bay (Chesapeake Bay Foundation, 2004) where water qual- ∗ Corresponding author. Tel.: +1 301 504 6417; fax: +1 301 504 8162. E-mail address: mulbryw@ba.ars.usda.gov (W. Mulbry). 0925-8574/$ – see front matter. Published by Elsevier B.V. doi:10.1016/j.ecoleng.2005.12.009
  • 2. 322 e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 ity has declined dramatically due to eutrophication (Horton ters (Adey et al., 1996). The system consists of an attached algal and Eichbaum, 1991). Ecologically sound manure manage- community growing on screens in a trough through which ment on farms is vital to minimize losses of valuable plant polluted water flows. The algal community is a high diversity nutrients and to prevent nutrient contamination of the sur- system with 30 or more species of algae, along with associated rounding watershed. The challenge for ecological engineering microbes and micro-invertebrates. When operated at neutral is to develop technologies that can economically treat manure pH values, this living community provides most of the water as a waste source and, ideally, transform it into a useful treatment by uptake of inorganic compounds in primary pro- byproduct. duction and breakdown of organic compounds in community An alternative to land spreading of manure is to grow crops respiration (Adey and Loveland, 1998). of algae on the N and P present in the manure and convert This system is modeled on the algal turf community found manure N and P into algal biomass. Most efforts in using on coral reefs, which have some of the highest recorded algal production for wastewater treatment have been focused metabolisms of any ecosystem (Adey and Goertemiller, 1987). on treatment of municipal waste effluents using suspended Metabolism of the algal turf scrubber is controlled by manip- microalgae (Benemann and Oswald, 1996; Green et al., 1995). ulating water depth and flow rates, use of natural or artificial Wastewater treatment using attached algae (periphyton) has light sources, control of herbivores and frequency of harvest. also been reported and has potential advantages in how the All of these factors can be adjusted to maximize metabolism algal biomass is harvested and dried (Hoffman, 1998). One and, thus, to maximize water treatment capacity. Harvest- technology using periphyton, termed algal turf scrubbers (ATS) ing is particularly important since this action rejuvenates the (Adey and Hackney, 1989; Adey and Loveland, 1998), is rela- community and leads to high growth rates. In fact, biomass tively simple in design and yields an algal biomass that can production rates of algal turf scrubbers are among the high- be easily harvested on adapted farm-scale equipment. Previ- est of any recorded values for constructed ecosystems (Adey ous work in this laboratory has demonstrated the use of ATS and Loveland, 1998). Many pollutants are taken up in algal periphyton to remove N and P from dairy manure effluents biomass and are removed from the system through harvest (Kebede-Westhead et al., 2003; Wilkie and Mulbry, 2002) as (Adey et al., 1996). If these pollutants are not toxic, the har- well as the use of the resulting biomass as an organic fertil- vested material can be processed into a useful byproduct such izer (Kebede-Westhead et al., 2004; Mulbry et al., 2005). The as a fertilizer or feed. If the pollutants are toxic, the harvested purpose of this paper is to assess the economics of ATS treat- material must be disposed of, usually through land filling or ment technology at the farm-scale for a hypothetical 1000-cow incineration. dairy. 3.1.1. Operating parameters The proposed treatment system (Figs. 1 and 2) is designed 2. Treatment goals on the basis of operations at the Dairy Research Unit of the USDA/ARS facility in Beltsville, MD (USA) (Wilkie and Mulbry, Within the economics and technology appropriate to farming 2002). In this confined animal operation, manure, urine, saw- systems, manure treatment systems should: dust (used as bedding material) and variable amounts of water are mechanically scraped from the barns into an underground (1) Achieve >80% reduction of atmospheric emissions sump on a continuous basis. This mixture (about 12% total (ammonia-N, methane, odor compounds) from manure. solids (TS)) is pumped to a screw press separator where the (2) Concentrate and stabilize nutrients from manure effluents majority of solids are removed, and the manure effluent (about so that the nutrients can be efficiently recycled on-farm or 5% TS) is fed at intervals to an anaerobic digestor for biogas exported off-farm. production. The digested effluent is subsequently stored in (3) Operate year-round so as to greatly reduce or eliminate an open lagoon prior to land application in the spring and fall. storage of manure effluent in lagoons. The proposed system assumes that one-third of the manure (4) Accommodate a wide range of dairy effluents with variable N and P are lost due to ammonia volatilization in the barns nutrient and solids content. and/or removed with manure solids during solids separation (5) Achieve >80% recovery of manure N and P at an overall prior to treatment of the manure effluent (Fig. 1) (Chesapeake cost of <$5 per pound N ($11 per kg N). Bay Foundation, 2004). Manure solids are composted prior to land application on- or off-farm. The remaining two thirds of the manure N and P (200 g TN and 40 g TP day−1 cow−1 or 3. Description of the proposed system 73,000 kg TN and 14,600 kg TP year−1 for 1000 dairy cows) are pre-treated by anaerobic digestion followed by algal treatment 3.1. Algal turf scrubbers using an 11 ha system. In Maryland the algal system could be operated for approximately 9 months of the year with reduced Algal turf scrubbers are a new technology for treating waste- productivity in the fall and winter months coinciding with water that utilize multi-species assemblages dominated by reduced light levels. Under this scenario, all digested manure benthic, filamentous algal taxa (Adey and Loveland, 1998). This effluent is treated immediately except for material that is col- technology was developed by Dr. Walter Adey of the Smithso- lected and stored during the three coldest months (approxi- nian Institution and has been shown to be effective for improv- mately December–February). This growing season would obvi- ing the water quality of agricultural runoff (Adey et al., 1993), ously vary with geographic location and affects the size of the domestic sewage (Craggs et al., 1996), and industrial wastewa- treatment area.
  • 3. e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 323 Fig. 1 – Schematic diagram of nutrient flow in the proposed treatment system. Manure from dairy cows in free-stall barns is mechanically scraped (or flushed with water) and the resultant manure slurry is subjected to a solids separation step prior to treatment of the solids by composting and treatment of the effluent by anaerobic digestion and algal scrubbing. Values for input N and P, milk N and P were adapted from Van Horn et al. (1994, 1996). Biomass from the algal scrubbers is either recycled back into farm operations (as a feed supplement or fertilizer) or exported from the farm. Fig. 2 – Schematic diagram of 1 ha ATS unit with associated equipment and water reservoir. Manure effluent is added continuously to the equalization reservoir. Algal biomass is harvested weekly, removed from ATS effluent using a mechanical rake, dewatered with a screw press, and dried using a belt drier. A 1000-animal farm-scale system would be composed of eleven 1 ha ATS units that would share reservoirs and the harvesting, dewatering, and drying equipment.
  • 4. 324 e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 3.1.2. Manure characterization ple mechanical dewatering yields biomass containing 20% The absolute and relative concentrations of different compo- total solids. Algal biomass would be stabilized by drying nents in dairy manure are dependent on the breed of animal, to 90% solids (10% moisture) and would contain 40% C, amount and composition of feed as well as water use in the 7.5% N, 1.5% P and an ash content of about 15%. We esti- barns. Van Horn et al. (1994) summarized manure composi- mate an average biomass productivity rate of 22 g m−2 day−1 tion values from a variety of literature sources and we used (at 10% moisture content) (Kebede-Westhead et al., 2003). their value of 300 g TN excreted per cow per day. There is con- This value corresponds to field-scale productivity rates of siderable variation in estimates of the proportions of manure 220 kg ha−1 day−1 and 2420 kg day−1 (653,400 kg per 270-day N and P that are removed during solids separation. At the operating year) for an 11 ha treatment system for 1000 USDA facility, the solids content of the raw and separated efflu- cows. ents average 12% and 5%, respectively. For the purposes of this assessment, we assume that the solids separated manure 3.1.5. Biogas and energy production from anaerobic effluent contains 200 g of TN and 40 g TP per day per cow digestion of manure (equivalent to 73 kg TN and 14.6 kg TP per year per cow). Values for biogas and energy production from anaerobic digestion of dairy manure have been estimated previously 3.1.3. Manure loading rates (Van Horn et al., 1996, 1994). Assuming each cow produces Results from laboratory scale algal scrubbers using diluted 5.73 kg of manure volatile solids (VS) day−1 , and anaero- anaerobically digested dairy manure show maximum bic digestion yields approximately 350 L of biogas kg−1 VS, productivity (roughly 20 g D.W. m−2 day−1 ) at loading of biogas production is roughly 2000 L day−1 cow−1 . Assuming 2.5 g TN m−2 day−1 (Kebede-Westhead et al., 2003). We used biogas is composed of 60% methane with an energy con- this value for the average manure loading rate in the ATS. tent of 8.90 kcal L−1 , total energy production is estimated This corresponds to an approximate P loading rate of at 10.7 Mcal cow−1 day−1 (Van Horn et al., 1994). For a dairy 0.5 g TP m−2 day−1 . For this assessment, we assume 9 months farm with 1000 cows, the total energy production would be (270 days) of algal production per year. Using a yearly average 10,700 Mcal day−1 or 3.9 × 106 Mcal year−1 . of 2.5 g TN m−2 loaded on ATS per day, 270 days per year yields N and P loading rates of 0.675 kg TN and 0.135 kg TP m−2 year−1 (6750 kg TN and 1350 kg TP ha−1 year−1 ). Assuming that solids 3.1.6. Energy requirements for biomass drying separated manure effluent from each cow contains approxi- Harvested algal biomass (4000 kg per ha) would contain mately 73 kg TN and 14.6 kg TP per year (shown above), then roughly 5% solids. After dewatering (3000 kg water removed each hectare of ATS raceways will treat the yearly solids from 4000 kg harvested biomass) the algal biomass would con- separated manure effluent from about 92 cows. tain 20% solids (1000 kg per ha) and could be subsequently stabilized by drying to 90% solids (220 kg of dried product 3.1.4. Algal biomass characteristics and productivity per ha). The calculated energy requirement for drying 780 kg At a loading rate of 2.5 g TN m−2 day−1 , harvested ATS water from 1000 kg of dewatered biomass (using an energy biomass contains about 5% total solids at harvest and sim- consumption of 1.2 Mcal kg−1 H2 O) is 932 Mcal ha−1 day−1 . Table 1 – Capital cost estimates for manure effluent treatment system (for 1000 cows) No pre-treatment ($) Pre-treatment with anaerobic digestor ($) Site preparation, grading, compaction ($34,000 ha−1 )a 374,000 374,000 HDPE liner and installation costs ($33,000 ha−1 )a 363,000 363,000 Pumpb 93,000 93,000 Carbon dioxide sumps, diffusers ($4000 ha−1 )c 44,000 44,000 Roads, drainage ($7000 ha−1 )a 77,000 77,000 Electrical supply and distribution ($3000 ha−1 )a 33,000 33,000 Instrumentation and machinery ($500 ha−1 )c 5,500 5,500 Land cost ($3500 ha−1 )a 38,500 38,500 ATS Screen ($6090 ha−1 )a 67,000 67,000 Algal harvestera 85,000 85,000 Mechanical dewatering to 20% solidsd 35,000 35,000 Algal driere 135,000 135,000 Subtotal 1,350,000 1,350,000 Engineering and contingencies (15% of subtotal cost)c 202,500 202,500 Total direct capital 1,552,600 1,552,600 Working capital (25% of net operating cost)c 123,000 81,900 Total capital investment 1,675,600 1,634,500 a Values provided by Hydromentia, Inc. based on a proposed 11 ha 189,000 m3 day−1 treatment facility for agricultural wastewater. b Value based on a single 189,000 m3 day−1 pump for the 11 ha treatment area. c Benemann and Oswald, 1996. d FAN screw press (www.fsaconsulting.net/pdfs). e Belt drier with evaporation capacity of 9000 kg water day−1 to yield biomass with 10% moisture.
  • 5. e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 325 Table 2 – Annual operational cost estimates for manure effluent treatment system No pre-treatment ($) Pre-treatment with anaerobic digestor ($) Power for mixinga 165,500 165,500 Power for harvesting and dewateringb 13,200 13,200 Power for dryingc 173,300 0 Labor and overheadsd 62,400 62,400 Maintenance, taxes, insurancee 77,600 77,600 Total net operating cost 492,000 327,500 Capital chargef 139,100 135,700 Total annual costs 631,100 454,200 Cost per cow if biomass is driedg 631 454 Cost per cow if biomass is not driedh 454 454 Cost per kg N if biomass is driedi 8.70 6.20 Cost per kg P if biomass is driedj 43.20 31.10 Cost per kg N if biomass is not driedk 6.20 6.20 Cost per kg P if biomass is not driedl 31.10 31.10 Cost per kg of dried algaem 0.97 0.70 a Electricity cost for 189,000 m3 day−1 pump for 270 days (assuming $0.06 per kWh). b Electricity cost for mechanical rake harvester and FAN screw press. c Electricity cost to remove 7000 kg day−1 water from 11,000 kg day−1 wet biomass for 270 days assuming energy consumption of 1.389 kWh kg−1 H2 O at 46% thermal efficiency. d Estimate for two full-time equipment operators at $15 h−1 . e Calculated as 5% of total direct capital cost Benemann and Oswald, 1996. f Calculated as 8.3% of total capital investment. g Total annual cost divided by 1000 cows. h Total annual cost minus the cost of power for drying divided by 1000 cows. i Total annual cost divided by 73,000 kg N from 1000 cows. j Total annual cost divided by 14,600 kg P from 1000 cows. k Total annual cost minus the cost of power for drying divided by 73,000 kg N. l Total annual cost minus the cost of power for drying divided by 14,600 kg P. m Based on 653,400 kg algal biomass produced during 270 days. For an 11 ha treatment area and 270 days of operation per of the capital investment (the “capital charge”). The capital year, the corresponding total energy requirement would be charge (calculated here as the annual charge required to pay 2.8 × 106 Mcal year−1 . off the facility within a 20 year period at 5% interest) accounts for 21–28% of total annual costs. 4. Results 5. Discussion Estimated capital and annual operational costs for the pro- posed treatment system are shown in Tables 1 and 2. Costs 5.1. Comparison with alternative treatment are shown for a system without anaerobic pretreatment and systems for a system that includes anaerobic pretreatment. The major- ity of capital costs were due to land preparation, installation Other ecologically engineered alternatives to the algal turf of liner material, and engineering fees (Table 1). The major- scrubber exist for treating dairy and other types of ani- ity of operational costs were due to energy requirements for mal manure. Constructed wetlands have been tested exten- biomass drying, pumping water, and repayment of capital sively for this purpose (Cronk, 1996; Hunt and Poach, 2001; investment (Table 2). On farms using anaerobic pretreatment, Schaafsma et al., 2000). Wetland cells are usually positioned waste heat from burning biogas could be used to offset the after a lagoon or solids separator and they function primar- energy requirements of biomass drying (Table 2, column 2). In ily to reduce BOD and nitrogen. Although relatively short- addition, biogas combustion exhaust gas could then be recy- term studies (1–3 years duration) have demonstrated that con- cled back to the algal system to supply dissolved inorganic structed wetlands can effectively treat manure wastewater, carbon for optimal algal production and pH control (the costs their long-term capacity for phosphorus treatment is limited of such a carbon recycling system are not included in this anal- (Poach et al., 2003). ysis) (Benemann and Oswald, 1996). Under the best case (algal High-rate algal ponds also have been utilized for treat- system coupled with anaerobic digestion pretreatment), the ing manure effluent (Costa et al., 2000; Craggs et al., 2003; yearly operational costs per cow, per kg of N, per kg of P, and per Dugan et al., 1972; Goh, 1986; Olguin, 2003). In this technol- kg of dried biomass were $454, $6.20, $31.10, and $0.70, respec- ogy suspended phytoplankton and bacteria in slow moving, tively. Clearly, these calculated values are dependent on the shallow raceways are used to metabolize the manure pol- many parameters outlined in the assessment. The operational lutants. Advanced integrated high rate ponds have evolved costs are particularly sensitive to the costs for repayment from passive, facultative ponds and they are used for treat-
  • 6. 326 e c o l o g i c a l e n g i n e e r i n g 2 6 ( 2 0 0 6 ) 321–327 ing domestic sewage (Green et al., 1996, 1995; Nurdogan and municipal wastewater treatment facilities in this case) to Oswald, 1995). Given their demonstrated performance in treat- obtain pollution reduction credits from sources (dairy farm- ing other types of wastewater, high rate pond technology has ers in this case) that can reduce their nutrient contribution to significant potential for treating dairy manure effluent. the watershed at a lower cost (Greenhalgh and Sauer, 2003). Finally, Hillman and Culley (1978) described a duckweed (Lemna sp.) system for treating dairy wastewater (Hillman and 6.1. Nitrogen credit Culley, 1978). A hypothetical design was proposed for a 100- cow farm operation, utilizing a sequence of lagoons, but no A range of N credit values have been cited in different stud- empirical performance data was given. ies and models relevant to the Chesapeake Bay watershed. Thus, alternative treatment systems have been proposed Greenhalgh and Sauer used relatively conservative values of and tested. Unfortunately, however, very few published stud- $2 and $5 per lb N ($4.4 and $11 per kg N) among the different ies report economic costs for treatment systems. Hammer et options tested in their model on the economic and environ- al. (1993) reported some data for a swine wastewater con- mental impact of different policy options to reduce agricul- structed wetland in Alabama but only capital costs were given. tural nutrient inputs into the Mississippi River and Gulf of The total cost for about 6000 m2 of constructed wetland was Mexico. Values for potential nutrient trading credits may also $12,800. Interestingly, an old study projected costs of $70 per be developed from incremental cost estimates for upgrading ton of dried algae for a high-rate pond system (Martin and municipal wastewater treatment (MWTP) in the Chesapeake Madewell, 1971) to treat waste from poultry, swine, and cat- Bay watershed (Chesapeake Bay Program, 2002). Values ranged tle operations. However, drying costs were not included and from $8 per lb N ($17.60 per kg N) for annualized incremental an updated analysis is needed to assess the viability of this MWTP tiers 1 and 2 targets (to achieve effluent discharge levels alternative. of 8 ppm) to $14 per lb ($30.80 per kg N) for annualized MWTP tier 3 costs (to achieve effluent discharge levels of 5 ppm). For 5.2. Byproduct value of ATS algae dried algal biomass containing 7.5% N, N credit values of $2, $5, $8, and $14 per lb N correspond to $0.33, $0.82, $1.32, and As no market currently exists for manure-grown algal $2.31 per kg, respectively, for values of dried algal biomass. All biomass, our cost analysis does not include any value for but the lowest value would cover the projected cost of manure the biomass generated during manure treatment. However, treatment using algal production. there are a variety of potential uses for the algal biomass from manure treatment. Fresh dewatered biomass could potentially 6.2. Phosphorus credit be mixed in with animal feed (and substituted on a protein basis for soybeans) (Wilkie and Mulbry, 2002). Although this Corresponding values for P treatment credits are $5–7 per lb P use for the biomass would avoid drying and transportation ($11–15 per kg P) (Greenhalgh and Sauer, 2003). The value of $5 costs, such use would be relatively low value and the poten- per lb P was reported to be equivalent to MWTP cost for achiev- tial exists for disease transmission. Dewatered biomass could ing 1 ppm TP and $7 per lb P was reported to be equivalent also be bulked with other agricultural wastes and composted. to MWTP cost for achieving “<1 ppm” TP. Although the values This use would be of little direct value but would also avoid from potential upgrade costs wastewater treatment to achieve drying and transportation costs. improved P discharge limits are somewhat difficult to separate Although more expensive to produce (Table 2), dried algal out from costs of improved N treatment, the Chesapeake Bay biomass is considerably easier to utilize because the nutrients report separates out an incremental cost for TP reduction of are concentrated and stabilized, pathogens are eliminated, about $1 per kg P (Chesapeake Bay Foundation, 2004). How- and it is easily ground for different formulations. Recent stud- ever, nutrient trading credits for P reduction would be about ies focused on use of the dried biomass as an organic fertilizer seven-fold less than N credits since the algal biomass contains demonstrated that it was equivalent to a commercial organic only 1% P. A credit of $11 per kg P would be equivalent to only fertilizer with respect to plant mass and nutrient content $0.11 per kg dried algae and would represent roughly 10% of (Mulbry et al., 2005). Although the composition of the dried treatment costs. biomass varies with loading rate, heavy metal content is well below regulatory limits (Kebede-Westhead et al., 2004). The home consumer market is the most attractive with respect to 7. Conclusion price with retail prices of $2–3 kg−1 for comparable organic fer- tilizers. However, the pricing at which the dried algal biomass For perspective, the cost of manure treatment must be com- could successfully penetrate this market is unknown. pared with the profits from dairy operations. Johnson and coworkers surveyed 36 dairy farm owners in Maryland for the years 1997–2003 and found long-term annual profits of about 6. Potential for nutrient trading credits $500 per cow (Johnson et al., 2005). Based on this relative value, costs of treatment projected in this study for an ATS system Beyond any value that the algal biomass may have as a fertil- are very high and would consume most profit ($454 per cow for izer, feed supplement, or chemical feedstock, there are other algal system coupled with anaerobic digestion pre-treatment) potential sources of revenue to offset the costs of manure or exceed profit ($631 per cow for algal system without pre- treatment. Nutrient trading is a market-based approach that treatment). However, the economic balance becomes more allows pollution sources with high treatment costs (such as favorable if values from algae as a byproduct (e.g. fertilizer sale)
  • 7. ecological engineering 26 ( 2 0 0 6 ) 321–327 327 and nutrient trading credits can be realized. In addition, there Goh, A., 1986. Production of microalgae using pig waste as a are many opportunities for agricultural grants or cost-sharing substrate. In: Barclay, W.R., McIntosh, R.P. (Eds.), Algal at the state and national levels that could defray capital and/or Biomass Technologies. Cramer, Berlin, pp. 235–244. Green, F.B., Bernstone, L.S., Lundquist, T.J., Oswald, W.J., 1996. operational costs. The USDA’s Environmental Quality Incen- Advanced integrated wastewater pond systems for nitrogen tives Program (which provides up to 75% cost share of capital removal. Water Sci. Technol. 33, 207–217. costs to a maximum of $450,000 per 5 year farm bill cycle) Green, F.B., Lundquist, T.J., Oswald, W.J., 1995. Energetics of would be important in this regard. These kinds of economic advanced integrated wastewater pond systems. 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