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The modular-designed gasifier was assembled in seven hours, the electrics were completed
on the third day, and the refractory was being cured by the fourth day. The system was running
as designed with turkey litter as the fuel on the fifth day.
Currently, heat generated by the gasifier is available to provide a consistent warm temperature
in the turkey houses. This heat will replace the conventional method of using propane heaters to
maintain the required temperatures in the houses. While the reduction in cost of propane can be
easily measured, another of the project’s goals is to be able to quantify the improvement in
animal health and growth. This increase is due to the superior environment supplied by the
clean air from the gasification system versus the moisture-laden heat from the propane heaters.
A small turbine will be added to produce electricity later this summer. At that time a portion of
the heat generated from the power system will be directed to the hot oil heat exchanger and used
to heat the turkey houses.
The next stage of the project is to evaluate the energy production and byproducts as viable
sources of income. The measurement of the value of the system in each of these areas is critical
to the determination of the success of the project and the commercial value of the system. There
are various revenue streams or cost avoidance components to be quantified, including:
• Zeolite has been incorporated as a feed additive in a ration that is Generally Recognized As
Safe by the FDA. Tests will determine the level of Nitrogen retained in litter and ash with and
without zeolite inclusion and the effect of zeolite on bird health and feed conversion.
• Manure handling costs – the value of manure as a saleable product or the cost associated
with disposal (which is the situation in many regions) are determined by the cost to handle and
transport the material. This cost must be quantified to determine the value of drying or gasifying
the manure.
• Value of manure versus value of dried product as a fertilizer versus value of biochar/ash
product.
• Cost and risk associated with mortality disposal versus including them in feed of gasifier.
• Cost avoidance of propane heat of turkey houses by replacement heat from the gasifier.
• Improved bird health, growth, and feed rate by improved environment due to clean dryer air
from gasifier versus higher moisture irregular temperatures by propane heaters.
• Value of power generated – kWhrs produced and price.
• Amount of labor involved in operating system versus operating the houses with the current
method.
• Value of carbon credits and potential value of biochar.
• Evaluation of different potential operating scenarios – use of corn stover and wood waste as
fuel, value of manure as ash or as dried fertilizer, etc.
It is thought that the most beneficial economic value for the project will be from the sale of the
pathogen-free biochar ash (see www.biochar-international.org for additional information on
biochar and its many benefits, including carbon sequestration).
The turkey industry produces millions of tons of manure and litter annually. In some areas,
Minnesota notably, turkey litter is considered to be beneficial when land applied; in other areas,
nutrient loading of the soil from land application of litter is the grower’s biggest challenge. For
instance, in the Chesapeake Bay Area, land application of manure is stringently regulated to
prohibit nutrient loading; it can be very costly to dispose of the litter through transportation out of
the area. Other regions of the country have fewer restrictions but encounter strong
environmental pressure to reduce land application.
New upscale subdivisions are being built near P & J Product’s site. There is some concern
that in the future, land application of litter may not continue to be an accepted practice. As multi-
generational turkey growers with a strong commitment to the industry, the Zimmerman’s are
partnered with Coaltec and Xcel Energy in this gasification project in an effort to proactively
assure that they remain good neighbors in their community.
For more information about the installation of this project, Click Here
on the third day, and the refractory was being cured by the fourth day. The system was running
as designed with turkey litter as the fuel on the fifth day.
Currently, heat generated by the gasifier is available to provide a consistent warm temperature
in the turkey houses. This heat will replace the conventional method of using propane heaters to
maintain the required temperatures in the houses. While the reduction in cost of propane can be
easily measured, another of the project’s goals is to be able to quantify the improvement in
animal health and growth. This increase is due to the superior environment supplied by the
clean air from the gasification system versus the moisture-laden heat from the propane heaters.
A small turbine will be added to produce electricity later this summer. At that time a portion of
the heat generated from the power system will be directed to the hot oil heat exchanger and used
to heat the turkey houses.
The next stage of the project is to evaluate the energy production and byproducts as viable
sources of income. The measurement of the value of the system in each of these areas is critical
to the determination of the success of the project and the commercial value of the system. There
are various revenue streams or cost avoidance components to be quantified, including:
• Zeolite has been incorporated as a feed additive in a ration that is Generally Recognized As
Safe by the FDA. Tests will determine the level of Nitrogen retained in litter and ash with and
without zeolite inclusion and the effect of zeolite on bird health and feed conversion.
• Manure handling costs – the value of manure as a saleable product or the cost associated
with disposal (which is the situation in many regions) are determined by the cost to handle and
transport the material. This cost must be quantified to determine the value of drying or gasifying
the manure.
• Value of manure versus value of dried product as a fertilizer versus value of biochar/ash
product.
• Cost and risk associated with mortality disposal versus including them in feed of gasifier.
• Cost avoidance of propane heat of turkey houses by replacement heat from the gasifier.
• Improved bird health, growth, and feed rate by improved environment due to clean dryer air
from gasifier versus higher moisture irregular temperatures by propane heaters.
• Value of power generated – kWhrs produced and price.
• Amount of labor involved in operating system versus operating the houses with the current
method.
• Value of carbon credits and potential value of biochar.
• Evaluation of different potential operating scenarios – use of corn stover and wood waste as
fuel, value of manure as ash or as dried fertilizer, etc.
It is thought that the most beneficial economic value for the project will be from the sale of the
pathogen-free biochar ash (see www.biochar-international.org for additional information on
biochar and its many benefits, including carbon sequestration).
The turkey industry produces millions of tons of manure and litter annually. In some areas,
Minnesota notably, turkey litter is considered to be beneficial when land applied; in other areas,
nutrient loading of the soil from land application of litter is the grower’s biggest challenge. For
instance, in the Chesapeake Bay Area, land application of manure is stringently regulated to
prohibit nutrient loading; it can be very costly to dispose of the litter through transportation out of
the area. Other regions of the country have fewer restrictions but encounter strong
environmental pressure to reduce land application.
New upscale subdivisions are being built near P & J Product’s site. There is some concern
that in the future, land application of litter may not continue to be an accepted practice. As multi-
generational turkey growers with a strong commitment to the industry, the Zimmerman’s are
partnered with Coaltec and Xcel Energy in this gasification project in an effort to proactively
assure that they remain good neighbors in their community.
For more information about the installation of this project, Click Here
P & J Products - Gasification of Turkey Litter
