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*1. It needs to be recognized
that in the world of printed documents that some information is useful for
decades other information may be obsolete by the time it is printed.
This is especially true of information relative to regulations. If you
are dealing with regulations it is important to check at County, State and
Federal levels to be sure you have all the current requirements.
1. As herds get larger, the problem - manure handling -
cannot be ignored or solved by throwing more labor at it.
2. You also will find neighbors with environmental
concerns may dictate the nature of your required system.
3. The EPA, Department of Natural Resources, or other
agencies, may suddenly have and impact on your management practices.
Non-Point Pollution is widespread pollution commonly
attributed to agriculture caused by application of fertilizers, over
application or misapplication of manure, or general abuse of livestock or
crop environmental issues.
A. States are developing
laws that will require storage of manure with controlled spread times.
B. Other considerations
are being given to controlling application rate to protect the environment
from over applying animal wastes. Soil testing and recorded
application rates may be needed to protect yourself. There is work
on 300 units of phosphorus in soil as the maximum allowable - then no more
fertilizer (manure or commercial) would be allowed, 100 units are needed to
grow a good crop. With such a standard and accepted management
practices, a farmer would have protection against suits, for ground water
contamination or stream and lake growth caused by high nutrient content of
water.
4. A good manure system with barn and yard
planning will yield better herd health and better production. Cows
in mud or cows in manure don't maximize returns on investments, and
certainly don't assist in the esteem of a dairy operation. Dairy
operations will have to look good and create a good image of their product
to the consumer.
5. In the past 20 years, the primary reason for
installing a manure system has been convenience. But, the benefit of
eliminating the chore of daily hauling and spreading over a ten year
period adds up to a lot of dollars. Add that to a $50 - $60 / cow
per year gain in nutrients and a manure system decision cannot be ignored.
You will find that from the perspective of sustainable
agriculture, or nutrient cost, farmers with liquid manure systems
frequently look at their crops showing the results of good nutrient
management saying, "There is my profit." It is recognized that 75
percent of the nutrient value of a crop that is fed to animals, ends up in
the manure. Conventional spreading will return about 30 percent back
to the soil, 90 percent return is possible by applying at the proper time
and getting the nutrients into the soil. Valuing manure is not
simple. The N, P, K is generally valued at $60- 100/ per cow per
year, but other soil building capabilities of manure exist and are harder
to value. Some practitioners of good soil management feel the soil
building elements of manure are just as important as the dollar value of
the major nutrients.
You will find that manure will be processed and
recycled in many different ways in years ahead. It is being done
many ways on a number of farms today. Recycling it back to the soil
is the logical first phase. To do this well, a storage facility is
required which allows application at the proper time during the crop year.
Separation and reuse of the bedding is done on some farms. This
basically requires a system with lots of water and the entire barn
must be designed around the system. If a floor system is used 75 percent reuse of liquids can
be attained, but 25 percent new water is required for each flush to keep
separators working properly. A flush system has a severe weather
limitation and works best in warmer climates. Refeeding of any of the
components requires careful monitoring and must be limited to animals not
connected directly to the food chain.
Methane digesters have been a hope for many years.
They are most cost productive when the gas can be used for heat production
at the source. The production of electricity adds appreciably to the
cost of a system and requires extensive management and service with
limited pay back. The contract withy the utility will determine the
feasibility of the system.
Changing energy costs affect nutrient cost; the forward
march of technology will produce changes in manure management in the years
ahead. Today, making the best use of your home grown nutrient bank
with a reasonably priced storage and distribution system will help insure
your competitive position.
YOUR MANURE SYSTEM
This question can be answered by considering these
factors.
FACTORS for POSTON PUMP BEST
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Distance to storage is less than 150 feet.
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Bedding is used @ rate of one bale per ten cows.
Bedding is baled straw o r equivalent of chopped bedding.
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Power available is limited (10 hp maximum).
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Herd size up to 300 cows range.
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Farmer operated system, or dependable help.
FACTORS for IMPELLER PUMP BEST
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Storage is above ground or elevated above barn.
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Distance to pump exceeds 150 feet.
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Minimum bedding planned or needed.
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Bedding must be chopped or equivalent chopped straw,
etc.
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Three phase power available.
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Flush system being considered.
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Farm has hired labor doing chores and hired hands
change frequently.
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Milking parlor and free stall operation.
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System requires mixing or blending before transfer.
If a piston pump is to be used, select one that will
pump water as well as manure. The hollow piston type pump will pump
anything that should be pushed into a pipeline.
Care must be taken to control the material fed to the
pump. There are limits to the amount of bedding that can be added to
manure and there are limits to what a pump will handle. This
variable is highly dependent on pipe length.
PVC PIPE
Use SDR 35 pipe or heavier. Inspect pipe for
smooth inner surface.
NOTE: SDR stands for Standard Diameter Ratio and
SDR35 means the diameter is 35 times the thickness of the pipe wall.
Review the specifications required by the regulatory agencies in your
area. While SDR 35 pipe is classed as a free flow type of pipe it
has been used for pump fed pipe lines for decades. Pressure rated
pipes will rate a schedule 40,80 etc., and are typically water transfer
pipe.
PUMPING DISTANCES
Follow the Pipe Length Chart for system satisfaction.
Remember, these figures are maximum guidelines. Pumping to these maximum
distances will require tighter management of the system than if the system
can be installed with a shorter pipe. Systems with pipelines of 100
feet or less have consistently better performance, require less power,
last longer and have fewer problems than systems with longer pipelines.
In addition, management parameters can be stretched to allow you to do
more with the system. To understand this, consider the problems
which would occur with a hay baler with a 200 foot chamber. Just
because a particular manufacturer claims they have a pump that can pump
longer distances than another brand does not mean they have a better pump.
All of the significant brands use the same motors and the same pipe.
If you want to pump faster or push more bedding farther, it takes more
power. If you pump at the upper limit of
bedding, you can reach a point where the required pressure exceeds the
rating of the pipe. Nobody wants to experience a pipe that blows up.
If heavily bedded material from a calf pen or silo top must be pumped,
leave it in the gutter overnight to get more manure into it and then add
enough water so the material will not pack. REMEMBER, bedding under
pressure absorbs more water. When it comes out of the pipe it will
look like a fiberboard log. When it went in, it looked fairly
sloppy. The best advice is don't run questionable material through
the pump. A few wheel barrel loads or skid steer buckets of calf pen
manure easily be kept out of a system.
If you find a manufacturer who rates their pumps with a
shorter pipeline than others, it can mean they have higher standards of
what they expect in terms of performance and longevity and NO TROUBLE.
ELBOWS IN A SYSTEM
A 22.5 degree elbow in the pipe is at least equivalent to 10
feet of pipe when close to the pump and 25 feet when on the end of the
line. If a plug of calf pen manure comes sliding along, multiply
this factor by an additional 5 or more, depending on the plug. DO
NOT use a single section 45 degree elbow in a manure pipeline.
PUMPING UPHILL
Pumping uphill will require more power. Shorten
the recommended distances by a percentage equivalent to the rise in the
line in feet. Pumping uphill 10 feet should shorten the pipe length
rating by 30 percent minimum. Serious consideration should be given
to locating the pit or lagoon where it is not necessary to pump uphill and
protect the system from back flow.
PIPE INSTALLATION
Pipes need to be installed with a minimum a uniform grade
angle of 2 percent, 2 feet per 100 feet or more. Do not create low
spots in the pipeline. Low spots become settling points for sand,
gravel, and lime and are the point of trouble when lines plug. The
uniform slope provides successful washing of a line if non-organic
materials (sand, gravel, lime, etc.) build-up in the pipeline. Our
line cleaning experience has taught us that service options are a
need, not just an option. If a problem should occur in a system
years later, the system is designed to solve that situation as quickly as
possible -- with the least time and service necessary while keeping the
pipeline intact. Install and bed the pipe as per pipe manufacturers
instructions. See your pump Installation Manual.
BACK FLOW PROTECTION - PUMP PROVISION
All systems require a protective device at the pump in
the form of a pipe mounted knife valve or an internal valve in the pump
which closes when the service is necessary to restrict uncontrolled blow
back from the line whether caused by liquid at a higher level or stored
energy in the line in the form of gas. If the liquid level in the
storage is above floor level at the pump, uncontrolled flow may result if
the pipe is open to the pit. Even if the level of liquid in storage
is lower than the pump, an entire pipeful may flow back out through the
pump before the gas pressure in the line is released, This will
occur where a pipe is plugged on the storage end and is not remedied within
a day or two. As the manure begins producing methane and other
gases, the gas is stored in the line under pressure until one end or the
other allows the pressure to escape. With the cylinder and piston in
place, backflow through the pump will not occur. Removal of the
piston and cylinder will allow this pressure to be discharged up through
the pump hopper. This may occur during the removal process or can
happen after the cylinder and piston are removed and work begins to unplug
the pipe and disruption of a secondary plug near the pump occurs.
(CONSULT OPERATOR'S MANUAL FOR CYLINDER REMOVAL PROCEDURE.)
BACK FLOW PROTECTION - FLAPPER VALVE
If there is a slurry in the pit or tank and it is
necessary to control the back flow of slurry into the pipe during service
to the pump or failure of the pipe, a flapper valve shutoff is required at
the storage end of the pipe, Remember that service to the pump may
be required at the bottom of the pump, 7 feet lower than floor level or
service to a pipeline which is almost always at a level lower than the
bottom of the storage. The new N-TECH flapper is unique in that it
will not only automatically close, but it allows for the closing of the
flapper valve manually. It also allows inserting a cutoff in front
of the flapper to make it possible to remove the flapper door and service
the pipe while the liquid level is above the pipe level. Most of the
time it is difficult to get the storage emptied below the pipe level.
The new N-TECH flapper allows isolating the pipe with up to 3 feet of
liquid in the pit. Every liquid system must have a flapper on the
end of the pipe. Failure to do this makes service to the pump or
pipe a risky job.
BACK FLOW PROTECTION - KNIFE VALVE
In the event that the storage level of liquid is to be
above pump floor level an in-line Knife Valve is required. This
valve can be used in any system for positive shutoff of the line if it is
located within a few feet of the pump. When used as protection
against back flow from elevated storage, this valve with a ground level
control is installed as close to the end of the pipe as possible.
The N-TECH knife valve is equipped with a lever control for normal
operation and a heavy duty driver which is an assist in closing and
re-opening the valve. We've found that when you need to close a
knife valve, you don't have time to look for a big sledge hammer to pound
on a valve that hasn't moved in 10 years. Thus the Driver is part of the
valve. This valve is also available with a clean out port behind the
valve blade, making use of the usual ideal location of this valve to be
able to service the end of the pipe.
SYSTEM PROTECTION DEVICES
All systems should be protected with the proper devices
to fit the system design.
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If the pumping mechanism should be jammed or damaged
to prevent proper operation, back flow could occur if the pipe is not
equipped with a flapper valve on the storage end.
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If the flapper valve fails to close due to damage or
material build-up at the pipe end or any other reason, a second cutoff
is essential.
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The in line Knife Valve will provide positive shutoff
of any back flow of manure when needed and is required if the storage
level exceeds the level of the top of the pump hopper.
PUMP INSTALLATION LEVEL
Do not install the pump so that the gearbox and motor
are below floor level or at a level which might be flooded at any time.
Damage to the gearbox and motor can occur, as well as possible electrical
shock from submerged wiring. If you have an installation that
requires extra depth, ask your dealer about an extension kit. N-TECH
provides a simple yoke extension that allows an extra 1 1/2 feet in depth
and 2 feet of hopper length.
SERVICE PORTS
In order to adequately provide service to a pipeline,
access to the pipe is needed at 100 foot intervals. This is due to
the fact that high pressure washers working in the types of material that
is usually found in manure system pipelines start losing their
penetrating force beyond 100 feet and also the fact that 80 percent of
pipeline problems are on the pit end of the pipeline. As you can
then understand, a system using 150 feet to 200 feet or more of pipe with
no other access to the pipe than through the pump becomes a lengthy
service job in January. Placing the cleaning and flush port on the
line , flush out gravel, or enter the line with a high pressure line
cleaning device to unplug a pipe line, with a 100 foot head start.
This is also a device that can be added to any existing system.
This type of service port is a standard feature available on the N-TECH
Knife Valve.
FLAPPER VALVE INSTALLATION
In a liquid system, the bottom of the pipeline or the
level of the flapper device in the pit needs to be 18 to 24 inches off the
pit bottom. The pipe needs to enter the pit through the sidewall to
eliminate the need for elbows as is often done when bringing the pipe up
through the bottom. This practice is also consistent with the most
important factor in system design. KEEP THE PIPE AS SHORT AND AS
STRAIGHT AS POSSIBLE. In the event the pit must be emptied shortly
before freeze-up, leave enough in the pit to keep the valve covered with
slurry.
STACKING SLAB - PLUG BUSTER
In a stacking slab system, the pipe needs to come up
through the slab. If this can be dine without an elbow, do so.
If an elbow is needed, do not exceed 22.5 degrees and keep the elbow as
close to the surface as possible. An N-TECH plug buster attachment
on the end of the pipe will deflect the plug upward and help prevent the
plug which can resemble a 12 inch log, from sliding along the slab until
it encounters enough resistance to STOP, thus plugging the line.
This device also has a provision to allow inserting a length of pipe into
the plug buster to provide a higher discharge so manure can be pumped
directly into a spreader during the summer. Caution: The
pipeline may need protection from freezing in some areas. Two to
four inches of Styrofoam four feet wide can help protect from freezing.
The discharge must have sufficient cover for winter. A 20-30
diameter 3-4'
deep foot
pile is needed before freeze-up. 10 to 20 bales of hay or straw
broken and spread over the pipe or a foot of old silage will protect a
pipe until it covers itself.
PUMP VOLUME
While a piston pump is affected by the type of material
that is to be pumped, it is a positive displacement device that pumps a
specific amount each stroke. Unless the pump is worn from years of
use, or is limited by the lack of the material to feed into the piston
(dryer materials or heavy bedding) the pump will pump a consistent volume.
Equipped wit a 10 hp motor and pumping material between high liquids 12-15
percent solids on the maximum end, a hundred gallons per minute is
expected performance. This will mean emptying the hopper in 4
minutes. This volume will usually sustain a gutter cleaner moving at
up to 24 feet per minute from a tie stall dairy barn with once a day
cleaning. An average size skid steer loader equipped with a bucket
or scraping device will usually match the volume of the pump if scraping
is done daily while the pump is running. Again, keeping the pipeline
shorter will allow more pump speed and faster pumping. Higher
volumes can be acquired by adapting larger motors up to 20 hp 3 phase or a
twin 10 hp single phase arrangement. This extra power should not be
planned into a system to increase pipe lengths but to provide higher
volume for larger herds. If even larger volumes are required, two or
more pumps may be required.
GAS PRODUCTION
It must be remembered that all manure systems produce
gases. Any pipe or pit that contains manure will begin producing
gases after a few hours. Gas production will be greatest after 24 to
48 hours and may continue for 3-4 weeks. Pits and tanks whether open
top or covered, must be managed as "Confined Spaces". Do not enter
without proper precautions. Specific systems must be equipped with
warnings which relate to correct procedures for servicing these systems.
YEARLY MAINTENANCE
Annually, or whenever a storage pit is emptied, the
level needs to be dropped low enough to see the end of the pipe. If
solids are settling off the end of the pipe, they must be removed.
It is solids off the end of the pipe that slowly accumulate to where the
pile in front of the pipe begins backing up into the pipe to create a plug
in the pipe, or become an obstruction to a wad sliding out of the pipe.
It is our observation that most pipes plug in this manner. A good
agitation job, with flow directed at the end of the pipe, will correct
this condition and if done every time the pit or storage is emptied, will
prevent many potential problems in a pipeline. Most of the time
manure system problems are pipeline problems not pump problems.
COLD HOUSING
Cold weather will yield frozen manure during the
coldest weather in many of the northern areas of the nation. Frozen
manure does not agitate or pump. It will pack in a pipe and cause
other problems. Even in slush form, it requires large volumes of
water to thaw it out. When this happens the manure may need to be
removed from the barn via an alternative route, whether the manure system
includes a piston pump, impeller pump, a gravity flow pipeline, or is
designed to flush the system. A well designed barn will provide for
the removal of manure via an alternate route, in the event of this type of
problem.
There is considerable difference in the quality of
electric motors. Clues to the quality of a motor can be judged by
the brand name, service factor, and prices. In addition, certain
motors seem to do certain jobs better than others. Heavy starting
loads or peaks in the load on a motor often require the use of one motor
over another. Typically a capacitor type farm duty motor will
perform well on a piston pump. The motor must be able to perform
well on silo unloaders in cold climates. Ten hp. motors are usually
the motor size of choice. When the pump does not require the full 10
hp, it will run at a lighter current reading, but will have the torque
when it is needed.
If there are special requirements in the design of a
machine, the manufacturer undoubtedly will favor a particular motor that
has proven to meet the needs of that machine.
If the job requires a heavy starting torque an R.I.
motor is frequently chosen. The user must realize that an R.I. motor
requires frequent inspection of the brushes to prevent motor failure.
Annual replacement is normal even with short daily use.
An R.I. motor also exhibits and operating
characteristic that must be understood. This is especially important
in that this motor is very expensive and misuse gets very painful in the
pocketbook. The problem comes when the motor is made to run at higher
than normal full load current, and then stalled out. The motor has
stored up an internal charge that discharges through the brushes when the
motor stalls. the net result is that the armature is burned out.
When heavy starting or operating loads are encountered the next larger
size of motor is usually selected. However, when one hits the 10 hp hurdle
and single phase current is the only choice, there is very little that can
be done. Motor manufacturers have been introducing 15 hp. single
phase motors for the past few years, however, they are more than twice the
price of a 10 hp. Phase converters are available, but are expensive.
A twin motor arrangement may meet the requirements.
This arrangement will require a double control and
sometimes double wiring. The controls should be set up to prevent
simultaneous start up to prevent high demand peaks which can be quite
expensive.
In providing overload protection for the motor, the
breaker should be sized close to the full load current. A 42 amp full
load motor would be protected by a 45 amp breaker. this close
protection prevents the motor from overheating while the breaker cools
during the intermittent load cycle which is created in this type of pulse
load.
Consult a reputable electrician or trusted local motor
supplier for advice on local application and brands.
PISTON PUMP SYSTEMS
What factors determine
the success of a piston pump system?
The factors that determine this are the barn and
livestock conditions that must be built into the system, and the
requirements placed on the installation of the pump and pipe line (SEE
Pipeline Chart), and the expectation of the owner and whoever will operate
the system. The first two factors present issues that are easily
identified. the last factor can present the real incurables. To
try to accomplish this after the sale can be very frustrating.
The only real solution to power is to design a
system that will operate within the range of tested operating parameters.
If the system in question includes a manure pump, several items can be
adjusted to meet the power factor.
- Shorten the pipe line, to save power.
- Operate a system with predictable moisture content and keep
that moisture level high enough so the material in the line does not
start to compress. A little extra moisture also cuts the
stickiness.
- Slow the pump down in terms of strokes if it is a piston
pump.
- Minimize the size of the part doing the work.
- With piston pumps, the piston size and strokes per
minute are two factors which determine the power required. (Also, see
the distance charts provided by the pump manufacturer.) Greater
amounts of bedding will require larger pistons. Attention to
minimizing the amount of bedding required in the barn will provide a better
system and lower costs for the operation, and allow a smaller piston, thus
lowering required power.
- Grates on gutters, small free stalls in "group"
calf pens, chopped bedding, etc.
- The speed of a piston pump is important not only from
the direct volume speed relationship, but because of the activity provided
in the hopper and cylinder throat, as well as the snap or activity of the
piston and cylinder gates.
The installation and start-up of every motor requires
both voltage and amperage tests under full load. The voltage
test assures the proper voltage is available under full load. A one
volt drop in voltage results in a one amp. increase in current flow.
Overloading draws a heavy current, a heavy draw of current usually yields a
drop in potential power which requires even higher current and motor
failure. This process becomes destructive very quickly. The pump
should be set up to run at least approximately 10% under the full load current of
the motor. Full load is itemized on the name plate on the motor.
This operating cushion will give some protection if the material going into
the pump should become harder to pump. Stiff, sticky manure requires more
power than pumping water. One must realize that when a pipe line
has been pushed full of heavy bedded material and then ideal material or
near water is fed to the pump, the motor may work even harder than when the
heavier material was being pumped. This is caused because the
piston gets a full charge each stroke and the motor must push the heavy
material in the line a maximum distance each stroke.
Several factors affect the operation of a pump. To
operate effectively and be trouble free the material to be pumped must be
under control. The physical environment at the pump needs to stay
above freezing.
SAND-IMPELLER PUMPS
Should I use Sand For
Bedding and Liquid Manure System? Impeller Type Pumps
In recent years there has been an increase in the use of
sand for bedding in free stalls. Some have discontinued its use
because problems developed that users had not anticipated or in their
planning or lack of planning, they could not provide a remedy for the
problems. Before you begin using it or modify your facilities to use
it, a full look at all the aspects of its use are necessary.
At N-TECH, we hear some manufacturers making claims their
equipment works just fine with sand, but we've encountered sad stories of
farmers who have taken that assurance at face value and have found they ran
into problems. Below are a few of the problems you may encounter and
provisions you should provide if you use sand. Also, we relate a few
management techniques which can neutralize or prevent some of the problems
if followed consistently.
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Sand settles out of manure as soon as the consistency
reaches a flowable stage. The more it splashes the faster it will
settle. If you are agitating on one end of a pit, the sand will settle
out on the other end of the pit. Access into a pit needs to be
provided so that excess sand can be scooped out when settlings require
removal. This is a need even in reception pits. It can best be
provided by planning a ramp into the end of the pit or at least allowing a
removable break in the end wall for a future ramp. (It must be remembered
that this will be a "confined space" and requires adequate ventilation
before and during entry into the pit. Testing equipment for proper
oxygen and noxious gases must be used before entry and during work in the
pit.)
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Pipeline discharge ends need to be located so that sand
does not pile up in front of the pipe and provide blockage. Keep the
pipe 2 foot or more off the bottom. Do not end up with low spots in a pipeline
or elbows or risers with no provision to flush the pipe on the flat.
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Sand will cause a pump to wear faster. Parts which
will wear are the housing, impellers, nozzles, manifolds, and elbows that
change the direction of flow. Life of a pump is dependent upon the mix
of sand with the manure and the sharpness of sand particles. This life
may be diminished by a factor of 4 to 1 or more. Drive train bearings
must be pressure lubricated and seals must be maintained or changed
regularly to protect bearings.
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Agitation within the storage pit should be provided which
allows forcefully washing the materials to the pump. In large or long
pits, a sump at the pump a foot to two feet deep, 60 to 100 square feet in
area, will allow a more complete pump out cycle. To assure that sand
is picked up during agitation, the rule of 2 ft per second of movement must
be reached in all areas of the pit.
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When sand ends up in the large storage pit a concrete
bottom with exit ramp is needed. For every 100 yards of sand cycled
through the stalls, expect 100 yards of sand in the storage pit.
The larger the pit is, the more settling should be expected. Lack of a
concrete bottom will require removal by dragline, etc., an expense that can
be several thousands of dollars each time. Dragline use can also damage a
liner if clay was used to seal the pit. If this sand is pumped, it
will cause excessive wear on irrigation systems and may accumulate in
tankers requiring periodic emptying. A concrete bottom is a necessary
feature of any pit or platform.
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Pipelines must be sized to match pump performance.
The velocity of the material through the pipe should be more than six feet
per second. With this speed, material that has settled in the pipe will be
picked up and removed. The following figures represent accepted
guidelines within the pump industry.
6" pipe 500 gallons/minute
12" pipe 2100 gallons/minute
7. Whenever
possible, pipelines and hardware should be kept where they can be
disassembled and serviced to correct wear or plugging. Pipelines must
be straight through pipes. Risers or agitators must be removable to
allow cleaning.
8. Pit run
gravel may contain rocks that can damage a pump. While sand is ideal
in that it helps prevent cows from slipping on concrete floors and tends to
keep the hoof in good shape, small sharp rocks can injure hooves leading to
foot rot and other problems.
9. Although
sand may be a cheap material and readily available, it must be managed
appropriately and you must recognize the other costs associated with its
use. The choice of sand will be a very critical item in the overall
success of stall labor, husbandry and manure system management.
-
Pit run
gravel will have rocks which may create a host of problems and
will cause pump problems and will be the first material to show up in pits
and pipe lines.
-
Granular
structure is the next important factor. Coarse grainy sharp sand will
settle fairly fast and when mixed in a slurry creates an effective cutting
fluid in pumps. Sand of finer texture and flat or smooth grains will
stay in suspension better, and will cause less wear to pumps and pipelines.
While a porous material is important so that moisture which ends up in the
stall will disappear, it should not churn when a cow steps in it. It
is important to have a base material under the sand fill which will allow
water to pass down. Sand with clay in it usually packs to the point it
holds water.
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When
filling stalls, keep the sand level an inch or so below the curb.
Three to four inches of extra fill in the front of the stall is adequate.
A properly placed brisket board is also important to keep the animal back in
the stall, thus keeping manure and liquids out of the stall.
-
If you
have no other alternative to a non-organic bedding material like sand,
consider using a fine ag-lime. It is a material that packs in the
stall increasing the amount of time it will stay in the stall. It has
value in the field. It usually does not contain stones, etc., it is
fine enough to stay in suspension as well as can be hoped and some say it
helps control the odor. Use only a finely ground or settlings pond
type material. The use of sand retaining devices may help keep sand in
the stall, but you may lose some of the advantages of the sand.
10. A
recent development is the cow mattress which can be installed in free stalls
instead of the sand full. This large heavy duty bag is commonly filled
with ground rubber. Others fill the stall with ground rubber and cover
with similar heavy duty bag material. Rubber mats several inches of
thick or water beds are also available each with claimed advantages. Reports are that cows respond
well to this solution. Various suppliers have varying installation
requirements. Consult a reputable supplier. Compared to the cost
of adding sand regularly to the stalls and the problems associated with
pumps and then getting the material to the field, they are an investment
worth your consideration. The cover material will have to be replaced
in a period of time, and the fill may have or have additional material
added. Before using, determine what the disposal process is for rubber
material that may have to be removed from the stall.
11. In the
event sand is planned in a new or existing barn, a fiber/sand separator may
need to be planned into the system to remove the sand from the material
flow.
|
WARNING: Any time you
must enter a covered or uncovered pit or tank, realize you are
entering a CONFINED SPACE. The air needs to be tested and
monitored to prevent gas problems. FAILURE TO HEED MAY RESULT IN
INJURY OR DEATH. |
SAND-Piston
Pumps
Should I use sand for
bedding and liquid manure system? (Piston Pumps)
In recent years there has been an increase in the use of
sand for bedding in free stalls. Some have discontinued its use
because problems developed that users had not anticipated or in their
planning or lack of planning, they could not provide a remedy for the
problems. Before you begin using it or modify your facilities to use
it, a full look at all the aspects of its use are necessary.
At N-TECH, we hear some manufacturers making claims their
equipment works just fine with sand, but we've encountered sad stories of
farmers who have taken that assurance at face value and have found they ran
into problems. Below are a few of the problems you may encounter and
provisions you should provide if you use sand. Also, we relate a few
management techniques which can neutralize or prevent some of the problems
if followed consistently.
-
Sand settles out of manure as soon as the consistency of
the slurry reaches a flowable stage. The more it splashes the faster
it will settle. If manure containing sand is to be pumped through a
pipeline, there are two alternatives:
-
Keep the material stiff enough to carry the sand
in suspension or keep it very liquid and pump it fast enough with an
impeller pump so it won't settle in the pipe.
-
If the stiff route is followed, the material will
be too stiff for anything other than a piston pump. However keep the
pipe length to less than half the recommended lengths of the manufacturer.
The stiffer material will pump harder, thus the shorter pipe. The
shorter pipe will allow keeping the manure in a stiffer condition, thus
having a better chance to carry the sand out of the pipe, however, operating
conditions become very restricted, a single rain or flooding from a waterer,
or extra liquid from the parlor can provide a slurry condition where sand
will settle in the pipe. These settlings may create an immediate
problem or it may take several months before the pipe becomes plugged.
It must be remembered it is fairly easy to make a slurry a little more
sloppy, but once it is too sloppy the sand settles and it is nearly
impossible to bring it back to a stiffer range. If the manure coming
off the floor is good and sloppy as it often is from high production herds,
the sand will settle. Once the sand and gravel settle in a pipe,
either a solid plug will be required to push the material out of the line,
or it needs to be washed with liquids, a flow of six feet per second or
more. That translates into more than 2000 gallons per minute in a 12"
pipe. The
piston pump is a 100 gpm pump. A piston pump cannot flush its own
line.
The choice of sand will be a very critical item in the
overall success of stall labor, husbandry, and manure system management.
Pit run gravel will undoubtedly have rocks which may
create a host of problems, will cause pump problems, and will be the first
material to show up in pits and pipe lines.
Granular structure is the next important factor.
Coarse grainy sharp sand will settle fairly fast and when mixed in a slurry
creates an effective cutting fluid in pumps. Sand of finer texture and
flat or smooth grains, will stay in suspension better and will cause less
wear to pumps and pipelines. While a porous material is important so
that moisture which ends up in the stall will disappear, it should not churn
when a cow steps in it. It is important to have a base material under
the sand fill which will allow water to pass down. Sand with clay in
it usually packs to the point it holds water.
When filling stalls, keep the sand level an inch or so
below the curb, Three to four inches of extra fill in the front of
the stall is adequate. A properly placed brisket board is also
important to keep the animal from laying forward in the stall, thus ending
up with manure and liquids in the stall.
-
Sand can be a comfortable material in the stall and is
ideal to provide grit on the floor to prevent slipping by animals. It
is also ideal in providing a degree of wear to the hoof to maintain a
healthy hoof. However, sand which contains pebbles and rocks,
especially sharp pebbles, may cause hoof damage which can turn to hoof rot,
etc.
-
A recent development is the cow mattress which can be
installed in free stalls instead of the sand full, This large heavy
duty bag is commonly filled with ground rubber. Others fill the stall
with ground rubber and cover with similar heavy duty bag material .
Reports are that cows respond well to this solution. Various suppliers
have varying installation requirements Consult a reputable supplier.
Compared to the cost of adding sand regularly to the stalls and the problems
associated with pumps and then getting the material to the field, they are
an alternative investmnet6 you can make in your barn.
-
If sand is to be used with a piston pump, the pipeline
must be kept short, manure consistency must be managed carefully to avoid
excess water or sloppy conditions, the pipeline needs a definite slope to
the pit and proper sand needs to be selected.
-
The pumps can pump this manure with sand in it, but the
problem will be in the pipeline. The best advice is do not use
piston pumps in barns or systems using sand.
COLLECTION PITS AND AGITATION
What should I
know about collection pits and agitation assist systems?
Long reception pits and vertical pto or electric pumps
provide a solution for collecting manure from several scraping points and
allowing the material to be transferred to a major storage area some
distance from the barn site, up to 1000 feet away or more. Management
of these types of systems is an individual situation and will be dependent
upon the material that go into the pit.
Long reception pits typically require agitation at
strategic locations to move solids back to the pump where they can be
blended into the mass and pumped out of the pit. Two, three or more
agitators is no guarantee that total and complete agitation will occur.
The liquid content will be the biggest factor in determining success of the
system. Straw, sawdust or other organic bedding can typically be
compensated for by adding extra moisture. The rule of thumb is that
one pound of bedding will require the addition of one gallon of water.
Non-organic bedding, typically sand, is harder to handle
keeping the pit free from build-up. In fact, it may not be possible to
prevent the settling of sand in reception pits or storage, and provisions
may have to be made to remove those solids with a load we or backhoe.
The use of pit run sand may introduce rock to the slurry which can damage
pumps. Small rocks may also injure a hoof, leading to hoof rot and
problems.
The size of the collection pit determines the agitation
system that must be used to move material to the pump. wider and
deeper pits require more agitators than narrower structures. A Pit
that is 10 ft to 12 ft wide may require an agitator at every scrape in
point. A narrower pit four to six feet may only require a line to the
far end to provide backflow in the pit. Over the top lines and
agitators will not require service in the pit and should be used whenever
possible. The pit width and depth should be sized to allow use of a
small or medium sized skid steer loader as a last resort remedy to a
problem. This requirement includes the exit ramps. Slope of the
ramp will need to be 1 to 4 or less. A rough surface on this
ramp is necessary. If a sump is provided at the pump, a ramp out of
the sump is needed. When a smaller collection pit is used, it may be
advisable to attach to a larger receiving pit to acquire needed volume.
This pit can be a couple feet deeper than the pit.
To provide all that can be done with a pump, locate
remote agitator spouts beyond scrape in ports so that solids and fiber can
be moved back to the pump. Agitators must be located so that each
agitator is located within range of another agitator, This is
necessary to allow the agitator stream from one spout to keep sand washed
away from the other agitator location. It will also be necessary to
spend sufficient time working on problem areas with the agitators to wash
them to the pump. The pit should be designed with a one to two foot
deep sump eight to ten feet square at the pump to allow a cleaner wash
of the long pit floor.
Remember that the coarser sands will settle faster than
finer material. Fine ground or settlings type ag-lime may be used in
place of sand. It is finer than most sand and will not settle quite as
fast as sand. It also lacks pebbles and rocks. It will not be as
abrasive on cattle hooves. There is a strong economic value to the
lime in the manure instead of inert sand. Again, there are many types
of ag lime, choosing a correct material will determine whether it works
well.
Material in this type of pit can be loaded into tankers
for direct hauling to the field or may as is done in most cased, be pumped
to the major storage. Provision must be made to allow removal of sand
from storage by use of a loader or drag line. Concrete bottoms with
ramp allow use of a wheel loader to remove solids. Tankers need to be
rear fill front discharge to provide a flow through path. In tank
agitation is also advised.
All manure systems have limitations. Cold barns
in colder areas need to be designed to allow removal of frozen solids via a
door where they can be loaded into a solids type spreader.
Although sand is cheap, it has other operating costs.
For the longer term trouble free operation of a liquid manure system AVOID
SAND. If you use sand, there are a number of factors which must be
done correctly to give you the best chance for success. See the
following for a few of the issues.
Sand for
Bedding-Impeller Pumps
Sand for Bedding-
Piston Pumps
|
WARNING Instructions must be
provided to warn personnel to not enter pit without testing and
monitoring the air. These types of pits are CONFINED SPACES
and entry must be avoided. Failure to heed may result in
injury or death. Consult OSHA Guidelines. Entry should
only be made by peoperly6 trained personnel using appropriate
equipment. |
What should I
consider as my herd increases?
As herds increase in size, larger storage basins are
needed to handle the volume of material that comes from several hundred head
of dairy, beef or other livestock. As the size of the required major
storage increases, it is harder to fit into building layouts in terms of
initial fit or, later traffic patterns, and more so the esthetics of desired
visual and odorous environment.
In systems where a large reception pit or pits are
planned into the building layout, the major storage can be moved away from
the building site. With a proper vertical PTO pump driven by tractor
or electric, this distance can easily be in the 1000 to 2000 foot range, or
further.
Where smaller (10-20 hp) electric pumps, piston or
impeller are used, an intermediate storage of 90-120 days capacity can
provide a significant sized storage yet not be too large to fit building
layouts. This storage can be concrete lined in the earth storage,
above the ground storage tanks, or a form where half the storage is below
ground line and half is above ground. This type of containment can be
provided by using poured concrete ,on pre-cast concrete or steel panels.
The pumps to agitate and empty this type of structure are
available. While some limitation in total depth is necessary, the
advantage of a moderate sized structure set in the ground with wall
protection and agitation and pumping access at any point around the
perimeter is a definite operating advantage. Any time the total
storage reaches the million gallon volume, this concept is an excellent
choice. In some cases, it makes sense to pump to more than one major
storage facility, planning the storage to fit available acreage for
spreading and recycling nutrients. This concept allows a system of
storage faculties preventing the development of a single large structure
that is so large that agitation and emptying is a problem. The ninety
day capacity will provide sufficient volume to provide storage through the
winter months. Pumps used to fill tanks or feed irrigation systems can
transfer from 50,000 to 150,000 gallons per hour to the major storage where
it can be in a strategic location for injection or incorporation at the
ideal time for crop and nutrient needs.
For information on pumps and storage of in ground, above
ground, or in ground and above ground types, call N-TECH (715) 537- 9207.
AUGER SYSTEMS
What is the
proper use of augers and what are some design parameters?
-
Use of long, uncut bedding must be avoided.
-
Quantities of chopped straw, sawdust or shavings and
other materials without sufficient manure or liquid will not feed into the
auger or should not be fed into and auger
-
The auger incline should not exceed 35 degrees.
Additional angle slows up material flow, requires more power and cuts the
range of material the auger will handle. Excessive angle will prevent
the flow of liquids up the tube. The flow of material into an auger
must be controlled. An auger works best when it runs at about half
trough capacity. When the flighting becomes fully loaded, excessive
power required and the load spins with the auger and quits sliding up the
trough.
-
The auger is a single component in the manure transfer
system. Guards and shields must be provided to keep operators or
spectators away from the feed or discharge points.
-
AUGER ARE NOT DESIGNED FOR SOLID OR PEN MANURE OR WATER.
-
AUGERS ARE FOR HANDLING FREE FLOWING SEMI-SOLID MANURE.
-
It is best to feed material to the auger from the left
hand side of the hopper. This gets the material into the auger quickly
rather than the auger throwing the material across the hopper to reach the
side of the auger that pulls material down into the trough.
-
Observation of
N-TECH and competitive units shows a pattern of auger deterioration and troughs being
worn out in 3-5 years. It should be realized that an auger is a low
efficiency, high wear, transfer device. Use of sand will require
replacement sooner.
-
At N-TECH we have avoided installing augers in pits which
are supposed to provide several days of storage. It is our observation
that a high percentage of these efforts lead to trouble and will not work
unless all bedding is eliminated and adequate liquid is added to provide a
free flowing "liquid" slurry which is ideal for a small pump.
GRAVITY SYSTEMS
How can I operate a
gravity system effectively?
While making use of gravity is a simple natural
phenomenon, its use in a trouble free manure system must be done carefully.
Remember, a gravity system with 10 feet of elevation difference will yield
less than 5 psi pressure. While high liquid materials will move
freely, various bedding materials can yield surprises in a pipeline, even
large diameter pipelines Most organic bedding materials float in
liquids. Cornstalks, straw sawdust, etc. can fill the top of a pipe
allowing the liquid to flow underneath. If the floating mass can
create enough friction against the top of the pipe to hold the maximum
liquid level, sometimes several feet of head, the pipe may become blocked
when bedding may close the bottom opening. A slippery pipeline helps
prevent this. Plastic pipe is a better choice than concrete or tile.
To work effectively, this type of system requires a
consistently sloppy stream of material. Outdoor lots where drying and
freezing occur create materials that should not be pushed into a gravity
system. Those materials must be loaded and hauled or pushed directly
into the storage pit usually over a straight wall.
Gravity systems with too much slope seem to drain the
liquids through the pipe while leaving the bedding and solids in the pit or
pipeline. While the receiving pit can have considerable height, the
pipe needs proper slope.
It must be expected that production of gases will occur
in the pipeline. With the upward slope to the barn, most of those
gases, methane, carbon dioxide, CH4, and others will feed back up to the
collection pit. This process demands ventilation protection and
warnings of this hazard. Also, the pit must be identified as a
CONFINED SPACE with appropriate warnings and precautionary service
procedures.
Lime, sand and gravel become progressively worse as
non-organic bedding material in a gravity system. These types of
materials begin filling the pipeline from the low end back up into the pipe.
Gravity systems require a high liquid content, thus solids can easily settle
in the pipeline.
For hardware to improve the function of a gravity system
cal us at (715) 537-9207
INFORMATION
Do you provide
information about vertical electric design and purchase parameters?
Yes! Below is a summary of
information that will help you to make important decisions.
Several size Vertical Electric
Pumps are available from N-TECH. They are designed for motor sizes
ranging from three to fifty horsepower. As for intended use, they
range from pumping milk room and parlor wastes to handling 100,000 gallon
reception pits.
The expected usage ranges from
less than an hour per day to 10 - 20 hours per day. Several factors
must be considered in the process of selecting the correct pump for the
job.
The following gives a preliminary
view of pump selection.
Pump size is first choice:
Pit depth- 6ft -12
ft. N-TECH pumps are sized in two foot increments.
Volume- Determine the
needed volume.
Material- Some pumps are
designed to pump basically water, others can handle more solids.
Solids come in many forms. Fibrous materials may be bedding or feed
materials. Attempting to chop materials in a slurry is generally a
non-productive effort. Cutting knives have a short life and soon
become dull at which point chopping ends. N-TECH pumps are built
with a reverse saw tooth inlet to provide a shredding action on anything
large enough to not flow directly through the impeller. It is usually
more productive to chop bedding materials before they are used for
bedding. As fibrous materials increase, the most effective solution
is to be sure the pump is large enough to handle the type of flow which
will prevent clogging of the inlet or piping. A pound of bedding
requires a gallon of water to make it pump able
Power- Is a determining
factor, this should be dealt with correctly the first time a decision is
made. Having to up-size a pump because optimistic decisions didn't
work can be expensive. Three phase power, phase converters or PTO
power may be needed to do the job.
Duty- Operating
conditions affect the size and drive train requirements. A pump
which will run less than an hour per day pumping high liquids can be
a light duty pump. Pumps tied into flush systems or separators may
require 10 to 20 hours of operation per day. This can convert into three
to seven thousand hours of operation per year. Appropriate drive trains
must be selected to fit this need. This type of use also requires
installation of double pumps so that service will not interrupt the
schedule of the system.
Bearings- Marine bearings
are very effective on light or medium duty jobs. And they are easily
replaced in split form. A maintenance task requiring a half hour if
done before a complete destruction of the bearing. Ball bearings in
oil filled tubes can provide extended use and are best choice for
automatic systems. Outrigger seals can protect the bearings thus extend
the life, however, preventative maintenance to the seals should be provided
on a regular schedule to prevent breakdown. Bearings normally have a
high expected life if protected from slurry material. Seals may be
limited to a thousand or two thousand hours, depending on the type of
material being pumped, lubrication cycle, etc. Thus, they need to be
replaced regularly to protect the bearings. In larger operations, a
preventative maintenance service contract to provide this type of service
is very beneficial and cost effective.
|
Product list- expected uses to size pump |
|
MODEL |
TYPE |
USE |
|
DDP |
3-5 |
Use |
|
Vertical Electric 5/10 |
5-10 |
Hog operations.
Parlor and wash up water run-off.
Flush water separator.
Liquids less than 5% solids. |
|
Vertical Electric 5/10
(oil filled driveline) |
5-10 |
Separator or flush systems with automatic
controls, or systems operating more than 2 hours/day. |
|
Vertical Electric 10/15 |
10-15 |
Any of above.
Dairy Operations from free stall floor or
barn cleaner.
Limited chopped bedding, extra water added as
needed.
Liquids less than 8% solids. |
|
Vertical Electric 10/20 |
10-20 |
Same as 10/15 only this unit has oil filled
sealed drive shaft.
Needed on flush and separator application or
higher lift needed. |
|
Vertical Electric 30/50 |
20-50 |
Any of the above and heavier service jobs.
Reception pits to 20' x 40'.
Liquids less than 10% solids.
This pump is available with twin 20 hp
motors. |
Motor Sizing
When motors are sized to the pump, it must be recognized
that opening an agitator while pumping out can require extra amperage.
The motor must be set-up to either put full power into pump out or
agitation or handle both functions at once. Motor amperage can be
diminished by changing sheaves to slow pump down, or as is sometimes done
to use a smaller diameter agitator nozzle. Volume is directly
associated with required power or amperage. Raising the pressure
will cut volume, thus lower required amperage. Wiring must be done
by a qualified electrician to assure meeting appropriate codes.
Wiring which is a little light or a bit over length can yield low voltage.
Remember a 1 volt drop in voltage will yield a 1 amp increase in amperage.
This easily leads to motor overload.
Required Pump Openings
The minimum size holes required for pumps are indicated
below.
| Model |
Hole Size
(minimum) |
| DDP |
14 x 16 |
| 5/10 |
17 x 20 |
| 10/15 |
22 x 24 |
| 20/50 |
28 x 48 |
If a new system is being
created, design it with a 3 ft. wide 4 1/2 ft. long hole. This will
allow use of a variety of pumps over the life of the pit. The
opening should be in the middle of the longest wall to minimize agitation
distance and allow a circular swirl in the pit. It needs to be where
it allows removal and service of the pump. The best location is
where the most liquids accumulate, usually away from the scrape in port.
Pump ports need covers and barriers to guard openings.
It must be remembered that a barrier is required when the hole is open.
These are field installed and need to be built to withstand any expected
load plus additional safety factor. Holes in pits in areas with
freezing temperatures require tight lids. Cold air flows into pits
continuously. Pits with more than one hole can develop a draft
through the pit without lids. It may be necessary to maintain a
minimum of 3 feet of liquid during coldest weather to prevent the pump
from freezing.
Ceiling Height
To run the pump up the rail and provide service to the
impeller housing above floor level, the normal required ceiling height
will be pit depth plus 5 feet. Sometimes a dormer may need to be
built into the roof. Occasionally the pump is mounted in the hole
using a stationary mount bracket and the pump in turn will be lifted out
of the hole using a skid steer loader or other device. This may
require less ceiling height.
Pump Out Packages
To connect to transfer piping, it is advised that
connecting plumbing be done above floor level. Avoid creating in the
pit installation or service jobs.
|
WARNING ENTRANCE TO ANY PIT
IS A "CONFINED SPACE" ENTRY AND MUST BE DONE ONLY UNDER TEST AND
MONITOR OR PROPER VENTILATION PRACTICES. CONSULT YOUR OSHA
REGULATIONS FOR PROPER PROCEDURES. FAILURE TO HEED CAN RESULT
IN DEATH OR INJURY. |
Installation in a new pit
can be done with a minimum of risk, but still requires confined space
procedures. Once the system is in use, you must expect unsafe air in
the pit.
Water Source
A water hydrant
should be installed near pump site to allow adding water if and when it is
needed.
A frost free
unit is advised.
Pipe Systems
Four basic pipe
systems are used for pumping out of the reception pit.
|
|
Over the Top
Can be used to fill slurry spreader directly
or top fill of storage tank. |
 |
Top to Bottom
Can be used in warm areas or protected
building |
 |
Bottom Fill Pack
Designed to protect pipe and valves from
freezing |
 |
Bottom Connectors
Designed to engage when pump is lowered into
lowest position |
Special Conditions
If freezing is expected with the bottom fill, leave
enough in the pit to completely cover the housing flex tube or connections
and valve through the wall.
If bark or chunks of bedding material are used, design
the system with up and down or over the top pipe system as it allows some
service without lifting the pump. Piping also remains a full 6"
whereas the bottom fill requires stepping down to a 4" to obtain
flexibility of the tube.
N-TECH Vertical Electrical pumps are designed with an
agitation port which can be used as an alternate pumping outlet for
regular use or emergency situations. A variety of hardware is
available for these needs:
-
The over the top pack is an ideal accessory which can
be used to top fill a slurry tank or can be used to pump directly into a
slurry tank spreader.
-
Additional agitation can be obtained in a pit by adding
an extra agitation spout to pump back down into the pit on the far side.
The PVC pipe used to pump to the storage facility must
be 160 psi rating or greater. Although the pump will not create
pressures in excess of 60 psi, unexpected strains and service operations
might someday tax the line for the full pressure rating. Manure can
be pumped to open pit storage or above ground structures. Do not
exceed 40 feet of head.
Reception Pit
The reception pit must be large enough to hold at least
one days production of manure, 3-5 days is desirable, and liquids with
room for sufficient water to obtain proper final mix. Calculate the
amount of manure produced in a day and double for a minimum size pit.
Multiple sizes can be used for longer accumulation periods. DO NOT
OVER SIZE THE PIT OR AGITATION PROBLEMS WILL RESULT. Use pump
selection table for matching pump to pit size. When planning a
reception pit, use the tables to choose pumps and motors for a system.
Simple combinations of length, width, and depth will produce the volumes
shown. If possible stay in 6-8 feet depth ranges. Deeper pits
are harder to install and harder to service when solids accumulate.
When installing a pump in
a reception pit, the pump should be in the center of one wall of the pit.
Do not place pump in a corner. Being in the center of the wall will
allow maximum angle of agitation and maximum flow to pump inlet, in
addition to a fairly short distance to all points in the pit. The
location also establishes a current flow in the pit keeping a swirling
action. Being in a corner cuts agitation angle to less than 180
degrees, cuts flow to inlet and creates a corner where solids will pile on
top of the pump housing.
If a round pit is planned, mount the pump on an outside
wall. This provides best current flow in the tank and prevents a
dead area in the tank.
POWER
Baldor Rl 10-15 HP
When using the Baldor single phase 15 hp Rl motor, one
must remember it has a one hour rating at 15 hp. Longer periods of
use will generate internal heat in the motor and burn the windings.
If the motor operates at the amperage required for 10 hp, then it is rated
continuous duty. If electric conditions only allow 10 hp, then a
Mini-Shredder (if the manure is over 90 percent liquid) or a piston pump
must be used. Brushed must be replaced at 200- 300 hours.
Roto Phase
An alternative to single phase soft start motor would
be to use a Roto-Phase unit and standard 3 phase motors. The initial
cost would be slightly higher, but the Roto-Phase unit would allow
conversion of motors on feeding equipment to three phase, resulting in
considerable saving over the long run. In addition, any future
repair of motor would be expected to be less.
Twin Motors
Motor drives utilizing the two motors are available.
This combination allows use of standard motors and permits the pump to be
run with 20 hp or more. A special switch is used with these motors
providing phased starting and double motor protection.
PTO Drives
Larger jobs may require 20-50 hp electric motors or
twin motors as discussed. Even larger jobs can be done with electric
motor/PTO converter or driven directly with a PTO drive. These
drives utilize a 90 degree gearbox mounted on the top of a pump and
utilize a 540 or 1000 rpm PTO. This shaft length is limited to five
feet or so tractor location becomes a factor. If shaft extensions
are needed up to 20 foot extensions have been provided to allow keeping
the tractor out of the barn or off the slats.
Electrical Service
Motor starter, switch devices, etc. should be located
so that disconnected piping or connections will not direct a flow of
liquids at electrical devices.
Sand
The use of electrical pumps in systems allowing sand
into the slurry is not recommended. Normally, a larger pump is
required which can provide greater agitation to keep the sand in
suspension. Heavier iron to resist wear is also a consideration for
PTO type pumps.
Automatic Controls
Pumps installed with automatic on and off need a
secondary off timer to prevent the pump from continued running if the off
control fails. Marine type bearings will run only a few minutes
before they begin to melt after liquid level drops below the bearing.
Pumps which start automatically need a visible warning sign which states
"THIS UNIT STARTS AUTOMATICALLY WITHOUT WARNING."
Agitation
Reception pits which are not pumped out daily require
ventilation before and during agitation. Larger pits especially require
ventilation which is directed out of the building. Operators need to
understand that livestock and personnel can be at risk if they occupy a
building which has manure storage located under it and agitation is
performed without adequate ventilation to prevent gases from rising into
the building. An agitation warning should be posted near the pump to
advise personnel of the risk and proper operating procedures.
System Size
On large systems with several hundred animal units, it
is advisable to plan a double pump system. Either pump should be
set-up to do the transferring of material and secondly, can do agitation.
In the event of a problem or maintenance on one unit, the other is
available to do the job. This assures always being able to handle
wastes while repairing a motor, pump, or other hardware.
Service
PREVENTATIVE MAINTENANCE
Check coupler rings, housing condition, bearings and
other components to prevent breakdown. The marine type bearing is
easily changed. Replacement of shaft, impeller and housing because
of a failed bearing is expensive.
Service to pumps must be done above floor level.
Any service that must be done below floor level requires air testing and
ventilation before entering the pit and during the stay in the area.
OSHA regulations provide requirements for procedures that must be
followed. Anyone entering the pit should receive proper training
before attempting entry into any CONFINED SPACE. Some of the
requirements are:
-
Entry permit must be completed before entry.
-
Entry must never be made alone.
-
Two standby assistants must remain out of the
pit or CONFINED SPACE.
-
A safety harness, safety line, and lifting
device must be in place for immediate removal of service person if trouble
develops.
-
The air must be tested before and during entry.
-
Proper ventilation must be provided or a
breathing device must be worn and used.
Designer of the pit should provide a CONFINED SPACE
WARNING sign appropriate to the size, location, and other parameters
relevant to this need.
Provide LOCK OUT capability for the controls to
provide for safe service to unit when needed.
| PIT SIZES |
|
|
| high liquid (Hog or
equivalent) |
Less Liquid (Dairy) |
Pipe Length (max.) (See note
below)* |
| |
pit capacity |
gallons |
pit capacity |
gallons |
|
| 5/10 |
|
|
|
|
|
| 5 hp |
360 |
2700 |
|
|
50 feet |
| 7.5 hp |
600 |
4500 |
not recommended |
100 feet |
| 10 hp |
800 |
6000 |
|
|
150 feet |
| 10/15 |
|
|
|
|
|
| 10 hp |
1000 |
7500 |
800 |
6,000 |
100 |
| 15 hp |
1500 |
11,250 |
1200 |
9,000 |
150 |
| 20 hp |
2000 |
15,000 |
1500 |
11,250 |
200 |
| 20/50 |
|
|
|
|
|
| 20 hp |
2000 |
10,000 |
2000 |
15,000 |
100 |
| 30 hp |
4000 |
30,000 |
3000 |
22,500 |
200 |
| 40 hp |
6000 |
45,000 |
4000 |
30,000 |
300 |
| 50 hp |
8000 |
60,000 |
5000 |
37,500 |
400 |
* Consideration of pump size must be given depending
upon pipe length.
This is a factor in motor size.
SPECIFICATIONS
|
PUMP
MODEL |
HORSE
POWER |
BEARING
TYPE |
PIT
DEPTHS |
MAX PIT
SIZE
(W-L)
% liquid |
MAX DAILY
OPERATION HOURS |
|
DDP |
5, 7.5 |
MARINE |
6,8,10 |
8 X8 |
1 |
|
|
|
|
|
|
|
|
Vertical Electric |
|
|
|
|
|
|
5/10 |
5,7.5 |
marine |
6-10 |
8 x 10 |
2 |
|
5/10 |
5,7.5,10 |
oil filled |
6-12 |
8 x 10 |
10 |
|
10/15 |
10,15 |
marine |
6-10 |
10 x 16 |
2 |
|
10/20 |
10,15,20 |
oil filled |
6-12 |
10 x 20 |
10-20' |
|
20/50 |
20,30,40,50 |
oil filled |
6-12 |
20 x 40 |
10-20 |
|
|
(or two 10 hp, 2-15 hp,
2-20 hp, 2-25 hp) |
|
|
|
|
|
|
|
|
Hydraulic Submersible |
Req. Hyd
2000 psi |
|
|
|
|
|
8" |
10-12 gpm |
|
|
|
|
|
10" |
12-14 gpm |
|
variable |
8 x 10 |
1-2 |
|
12" |
12-15 gpm |
|
variable |
10 x 16 |
1-2 |
|
14" |
15-20 gpm |
|
variable |
10 x 20 |
1-2 |
|
Spec |
|
|
|
|
|
|
Vertical PTO |
60-180 |
|
6-12 ft |
40 x 60-180% |
cont. |
|
(Standard Mangum) |
|
|
60 x 100-92% |
|
I have an "Impeller
Transfer Pump." What are your recommendations?
Impeller pumps work best
with plenty of water. All material must be free flowing to properly
blend or mix in the pit. They are the best alternative when manure
to be pumped is of a mixed variety, such as outside lots and free stall
combinations. During periods when outside lots are dry, they can be
mixed with slurry manure and water for pumping. During cold periods,
partially frozen manure can be pushed into the reception pit, mixed and
pumped. When the frozen manure to slurry ratio becomes higher than
1:2 it may be necessary to allow manure to thaw in the pit overnight.
One point to remember -- once manure or water becomes frozen, it takes
more than a hundred times as many BTU's to change it from solid to a
liquid with no change in temperature, as it would to raise the temperature
one degree (c) as a liquid. When the ratio of frozen to unfrozen
becomes too high, an alternate method must be provided to handle the
frozen manure. When scraping into the collection pit, add sufficient
water to the pit before dumping frozen or dried material into the pit.
Manure must be in 90 percent moisture range or above to pump with an
impeller type pump. Manure directly off a free stall floor is close
to 80 percent moisture. To change from 20 percent solid to 10
percent will require the addition of one gallon of water to every gallon
of manure.
The following chart gives data as to the amount of
water required to raise the liquid content of varying mixtures.
Poultry manures vary widely and must be handled on individual conditions.
Many hog systems may have enough water to be pumped directly. Use of
an Impeller Pump and 6 inch pipe is the best choice for pumping manure
containing grit, sand or lime. The high velocity of material in the
pipe keeps the line flushed out. However, minimizing grit and gravel
will maximize the life of the pump. Excessive amounts of lime and
gravel will cause agitation problems in final storage.
A Shredder or Chopper Pump is not a cure-all for a long
straw situation. Long straw or hay is very difficult to cut once it
becomes mixed with liquids and manure. It should not be sold as a
method to chop bedding to facilitate removal from storage. Efforts
to promote chopper pumps for this purpose have not proven very successful.
The effectiveness of the chopping device deteriorates in weeks. It
is much easier to chop the bedding when dry with a bedding chopper than to
try to accomplish the job in the reception pit. Shredding, if it
must be done, is also done best with lots of water to carry the bedding.
There is no specific point at which manure changes from
wet to fluid or fluid to liquid. Manure with bedding added can be
high in moisture, yet remain as dry manure from the standpoint of
handling.
A general range of moisture content for manure without
bedding would be as follows:
75% - 80%
moisture - stiff, some during taken place for dairy, beef and swine
manure.
80% - 85%
moisture - fluid or semi-liquid, quick thick and slurry.
85% - 93%
moisture - liquid, fairly thin liquid at 90%.
93% - 97%
moisture - Irrigation consistency.
(Assumed Correct; Mid-west Planning Service Materials)
APPROXIMATE
AMOUNTS OF WATER REQUIRED TO INCREASE THE MOISTURE CONTENT OF ANIMAL
MANURES
|
Initial |
Changed To |
|
|
Moisture |
Volume |
Moisture |
Volume |
Gallons |
|
% |
Cubic Ft. |
Gallons |
% |
Cubic Ft. |
Gallons |
Added |
|
84 |
1 |
7.5 |
87 |
1.23 |
0.2 |
1.7 |
|
|
|
|
90 |
1.6 |
12.0 |
4.54.5 |
|
|
|
|
95 |
3.10 |
23.3 |
15.8 |
|
80 |
1 |
7.5 |
85 |
1.33 |
10 |
2.5 |
|
|
|
|
90 |
2.0 |
15 |
7.5 |
|
|
|
|
95 |
4.0 |
30 |
22.5 |
|
75 |
1 |
7.5 |
80 |
1.25 |
9.3 |
1.8 |
|
|
|
|
85 |
1.66 |
12.4 |
4.9 |
|
|
|
|
90 |
2.50 |
18.7 |
11.2 |
|
|
|
|
95 |
5.0 |
37.5 |
30 |
|
70 |
1 |
7.5 |
75 |
1.2 |
9 |
1.5 |
|
|
|
|
80 |
1.5 |
11.3 |
3.8 |
|
|
|
|
85 |
2.04 |
15.2 |
7.7 |
|
|
|
|
90 |
3.0 |
22.5 |
15 |
|
|
|
|
95 |
6.0 |
45 |
37.5 |
|
|
|
|
|
|
|
|
| Courtesy: Maddix,
Michigan State Univ. File No. 18.42 Info. Series 150 |
EXAMPLE: To change 75% moisture material to 80%, 1 cubic
foot would become 1.25 cubic foot and require 1.80 gal. Use the
above table to establish a general idea of amount of water needed.
Milking parlor and washing wastes can be utilized to accomplish this by
adding uniformly as manure is pumped.
What
are the Dangers of airborne gas when handling livestock?
▲DANGER
HAZARD RECOGNITION CHART OF AIRBORNE GAS WHEN
HANDLING LIVESTOCK
Courtesy of MWPS-18 Livestock waste Facilities
Handbook
|
GASES AND ODORS FROM STORED WASTES
Consider the quality of air inside enclosed
livestock buildings. Wastes stored under slotted floors may be
in the buildings long enough for bacterial action to produce gases
and strong odors. Odors can be a nuisance to producers and
cause complaints and even lawsuits by neighbors. Noxious gases
can irritate both livestock and operators, and can be harmful and
even lethal. Workers and visitors have reported nose, throat,
and eye irritations.
Atmospheric air is 78% nitrogen, 21% oxygen,
0.9% argon, 0.03% carbon dioxide, and smaller amounts of inert
gases. Air content is changed in livestock buildings.
Breathing uses oxygen and releases carbon dioxide. Oxygen
content in the air below 10% is critical. Odors are given off
from animal's skins, urine, and manure. Anaerobic
decomposition of manure in a pit releases additional noxious gases.
If ventilation is not adequate, concentrations of certain toxic
gases are detrimental to animals and operators. |
NOXIOUS GASES FROM STORED MANURE
Most gas generated in a confinement unit is
carbon dioxide, ammonia, hydrogen sulfide, and methane.
Organic compounds from uncontrolled decomposition of wastes include
amines, amides, mercaptans, sulfides, and disulfides; they are
odorous.
Hazardous dust, fumes, vapors, and gases are
air-borne, follow air currents, and therefore do not stratify
because of density. Hydrogen sulfide and carbon dioxide,
although heavier than air, do not concentrate at floor level, but
diffuse throughout the space.
In a confinement production unit ventilated
for adequate moisture control, noxious gases usually don't reach
lethal or even harmful concentrations except with ventilation
failure or vigorous pit agitation. |
PROPERTIES AND EFFECTS OF
NOXIOUS GASES (Gases listed are colorless.)
|
Gas |
Odor |
Explosive Range |
Odor
Threshold (b) ppm |
Maximum Allowable Concentrations
(c) ppm |
Concentration effect |
|
Min. |
Max. |
Level (d)
ppm |
Exposure Period (e)
Minutes |
Physiological effects (f) |
|
Carbon dioxide |
none |
- |
- |
|
5,000 |
20,000 30,000 40,000 60,000 300,000 |
-
-
-
30
30 |
ASPHYXIANT
Safe
Increased Breathing
Drowsiness, headaches
Heavy, asphyxiating
Could be fatal |
|
Ammonia
(NH3) |
sharp, pungent |
16 |
- |
5 |
50 |
400
700
1,700
3,000
5,000
|
-
-
-
30
40 |
IRRITANT
Irritation of throat
Irritant of eyes
Coughing and frothing
Asphyxiating
Could be fatal |
|
Hydrogen Sulfide |
rotten egg smell, nauseating |
4 |
46 |
0.7 |
10 |
100
200
500
1000 |
several hours
60
30
- |
|
|
Methane |
none |
5 |
15 |
- |
1000 |
500,000 |
|
Asphyxiant |
|
Carbon monoxide |
none |
- |
- |
- |
50 |
500
1,000
2,000
4,000 |
60
60
60
60 |
POISON
No defect
Unpleasant, but not dangerous
Fatal |
(a) A mixture of gas and air can explode with
a spark in the explosive range (% by volume).
(b)
About the lowest concentration at which odor is detected.
(c)
Maximum allowable concentration allowed by health agencies for workers in
8 to 10 hour periods.
(d)
Parts of pure gas per million parts of atmospheric air. Divide by
10,000 for % by volume: 20,000 ppm/ 10,000 2% volume.
(e)
The time for the effects of the gas to be felt by an adult human or a 150
pound pig.
(f)
Effects in adult human or 150 pound pig: lighter pigs are affected sooner
at lower levels.
Carbon Dioxide (CO2)
General Description
Carbon Dioxide is highly soluble in water. Normal
atmosphere contains about 0.03% which increases from manure to
decomposition and animal respiration, and which also decreases the oxygen
content. Carbon dioxide is most-usually nearly all of the gas
bubbles from liquid manure, lagoons, or oxidation ditches. The tough
foam bubbles on a malfunctioning oxidation ditch are also high in carbon
dioxide.
Human Responses
Carbon dioxide is not highly toxic in itself, mainly
contributing to oxygen deficiency or asphyxiation. Small increases
above normal seem harmless, but 10% causes violent painting, and above
this is narcotic even if there is adequate oxygen. At 25%, death
occurs after a few hours.
Animal Responses
At 4%, carbon dioxide increases the depth and rate of
respiration; 7%-9% can be tolerated, but with considerable discomfort.
Concentrations of 20% are not necessarily dangerous to 140-200 lb. pigs
exposed for about an hour. Pigs tend to recover completely after
returning to standard air composition. The average carbon dioxide
concentration in a normally ventilated hog confinement unit may be
0.06%-0.07%. Without ventilation, the level can rise to over 0.4% in
6 hours.
AMMONIA (NH3)
General Description
Ammonia is also highly soluble in water. It does
not burn readily, but mixtures of over 16% with air are explosive.
Ammonia is released from fresh manure and during
anaerobic decomposition. Its solubility in water is lowered when the
pH is raised, as by the addition of lime. Ammonia can be controlled
somewhat in liquid manure systems, where much of it dissolves in water.
High water solubility explains the greater ammonia odors in units with
litter on solid floors than in liquid manure units. Heated floors
promote ammonia production and release.
The odor from as little as 1 ppm can be detected and
identified. Ammonia begins to burn eyes at 25030 ppm. Above 50
ppm (0.005%) eye inflammation develops in chickens.
Dimethylamine, and amine, has the characteristic
pungent odor of ammonia and irritates mucous membrane and respiratory
tract.
Human Responses
Low concentrations irritate eyes and the respiratory
tract; more may cause suffocation; 0.5% is a dangerous level.
Animal Response
Ammonia is an irritant, and at concentrations up to
0.02%, induces sneezing, salivation, and loss of appetite, but no loss of
feed efficiency. Prolonged exposure may increase respiratory
diseases and pneumonia.
Ammonia can condense and subsequently oxidize into
nitrite or nitrate. These compounds may accumulate on the floor and
cause poisoning if ingested.
HYDROGEN SULFIDE (H2S)
General Description
Hydrogen sulfide is soluble in water, so it can be
controlled somewhat by high dilution of manure. The gas burns with a
bluish flame, and in a mixture with oxygen, can explode violently,
Hydrogen sulfide may be the most toxic gas associated with liquid manure
storage.
It is produced by anaerobic decomposition of organic
wastes. High concentrations can be released by agitation and pumping
of liquid wastes.
Pieces of paper impregnated with lead acetate solution
turn black in hydrogen sulfide. Hydrogen sulfide forms black copper
sulfide on copper, white zinc sulfide on galvanized steel, and black
discoloration of lead-pigmented white paint.
Human Responses
It is both an irritant and an asphyxiant. Low
concentrations severely irritate eyes and respiratory tract in an hour.
Concentrations of 1000 ppm cause immediate unconsciousness, and death
through respiratory paralysis unless artificial respiration is immediate.
The sense of smell can be rapidly fatigued by H2S.
High concentrations do not proportionally increase odor, so odor is not
always an adequate warning.
Animal Responses
High concentrations during agitation can cause death.
Hydrogen sulfide concentrations were reported as high as 800 ppm in
confinement hog houses during agitation and for several minutes
thereafter. One pit of poultry manure was agitated for 25 minutes,
and the hydrogen sulfide concentration at the entrance to the pit
was above 1000 ppm ( a lethal level) during most of the period.
Animals living at levels of about 20 ppm develop fear
of light, nervousness and appetite loss that decreases daily gain.
Symptoms at 50-200 ppm include vomiting, nausea, and diarrhea. With
adequate ventilation, the levels of hydrogen sulfide can be maintained
well below 20 ppm except, perhaps, during pit agitation.
METHANE (CH4)
General Description
Methane is not very soluble in water, is highly
flammable, and burns with a blue flame. It is most hazardous in a
highly explosive mixture with air in concentrations as low as 5%.
Being lighter than air, methane tends to rise and accumulate near the tip
of air stagnant corners or tightly enclosed manure storage pits
Methane dissipates fairly rapidly with some ventilation.
Ruminant animals exhale a minute amount of methane, but
most comes from manure decomposition, To produce significant amounts
of methane, the temperature must be in the range of 90-110 degree F.
The presence of hydrogen sulfide, mercaptans and other substances causing
strong odors indicates unsatisfactory conditions for methane production.
Human Animal Response
Methane normally is not considered a toxic gas.
Accumulations in stagnant areas of buildings or manure storage pits can be
asphyxiating, but explosions are more dangerous.
POTENTIALLY LETHAL SITUATIONS
Ventilation breakdown, with no natural drafts to
replenish the air, can cause death by asphyxiation from lack of oxygen and
increased carbon dioxide, by heat prostration, by poisoning from other
gases, or some combination.
Agitation of liquid manure that has been stored for
several months releases noxious gases and creates dangerous and possibly
lethal conditions, even with full ventilation. If manure under
slotted floors must be agitated with animals in the building, ventilate as
much as possible and watch for signs of ill effects.
Starting and oxidation ditch rotor in wastes that have
been stored over a week or two may also cause a rapid increase in gas
release.
Entering a storage pit is not safe. Death can
result from hydrogen sulfide or lack of oxygen. if an animal falls
into a pit, don't follow it. Enter a pit only after it has been well
ventilated; wear self-contained breathing tanks; have safety rope attached
and someone standing by to pull you out at the first signs of dizziness.
Methane accumulates in covered pits with only manhole
openings, creating explosive conditions. Don't introduce a flame or
spark unless the pit has first been well ventilated.
Vent engines and heaters to the outside to prevent
toxic carbon monoxide accumulations. Carbon monoxide (CO) is a
colorless gas about the same weight as air. It is in the exhaust of
gas engines and gas, oil, and coal heaters.
CONTROL OF NOXIOUS GASES
Prevent their Production and Accumulation:
Clean solid floors daily.
Keep litter or bedding dry. Ventilate to dry
wetted areas quickly, or add new bedding.
Do Not overfill a pit under slotted floors--have
at least 1' depth below the slats.
Add enough water to keep manure solids submerged.
When solids under a slotted floor are dried with forced
air, vent the heat and carbon dioxide released to the outdoors.
Exhaust at least some ventilation air along the sides
of pits, between the slats and the manure level, to remove some of the
gases.
Consider a standby generator for emergency ventilation
of a large confinement unit.
Install a power failure alarm.
Vent engine and heater exhausts to the outdoors.
Ventilate the building when starting and oxidation
ditch rotor or after "shock" loading the ditch. When possible, empty
the pit and add fresh water before restarting.
Maintain the pH of the manure in a pit at near-neutral
conditions (pH 7) to control odors--dissolving lime in the water helps.
Clean the pit regularly and add fresh water to cover residue and solids.
During cold night hours when doors are shut to conserve
heat, animals are resting on the floor, and ventilation fans are operating
at minimum capacity, consider air circulation fans to improve mixing of
indoor air.
CONTROLLING MANURE ODORS
Odor quality is a comparison with a know odor (rotten
eggs, unpleasant, sickening, etc.). Strength is the amount of fresh
air needed to dilute odorous air to the threshold odor level.
Occurrence includes frequency and total length of time
the odor persists.
To control odors, select a site where they'll be less
of a problem. Then is necessary, counter the cause, treat the
emissions, or both.
Some odorous gases are water soluble--keep manure
diluted to decrease odor strength and/or covered with water.
Ventilation dilutes odors to less objectionable
strength.
Aerate wastes to effectively control the generation of
odors--aerobic lagoons, oxidation ditches, and composting.
Cover wastes to prevent the release of odors to the
atmosphere. Covered pit storage and tank wagons plus soil
incorporation of wastes minimize odor nuisance. Covered storage may
be a floating crust on cattle manure, or a concrete lid on a tank.
Immediate plow down or chisel injection of wastes decreases odors from
field spreading and also decreases the loss of nitrogen by ammonia
volatilization.
Absorb soluble gases into water. Ammonia can be
absorbed in a water spray.
Absorb most gases with activated carbon, which is
particularly effective for low odor concentration but is expensive for
large air quantities.
Mask disagreeable odor by adding a pleasant one.
Masking is usually used only for special occasions, as
during hauling and spreading.
Filtering dust particles reduces some noxious odors.
It is usually impractical to eliminate odors from
animal production units. Schedule cleaning and manure hauling at times
least offensive to those living nearby. Let your neighbors know that
you recognize odor problems and are trying to minimize them.
Remove odors in clothing by heating them in an exhaust
oven for an hour or so at about 200 degrees F.
Chemical treatment can reduce odors. Hydrated
lime reduces production of hydrogen sulfide and carbon dioxide, but
increases ammonia liberation and therefore decreases fertilizer value.
Chlorine stops bacterial action, and therefore reduces odors, but it also
stops treatment. Both treatments require relatively large amounts of
chemicals, have some disadvantages results and are at best temporary cures
to odor problems. Beware of pills or potions claimed to eliminate
odors.
Hazard
Recognition Chart of Airborne Gas When Handling Livestock
Courtesy of MWPS - 18 Livestock Waste Facilities Handbook
MANURE QUANTITIES, NUTRIENTS AND RELEVANT
ITEMS
Manure- refers to feces and urine
Waste - refers to manure with added bedding, water, feed
stalks, and other debris
-
A 1000# animal produces 9.9 gallon of manure daily
(approx. 10 gal.)
-
A 1500# animal produces 14,85 gallons of manure daily
(approx. 15 gal.)
-
Dairy manure is 87.3 percent moisture or 12.7 percent
solids.
-
Up to 15 percent solids or 85 percent moisture manure has
fluid handling characteristics.
-
Up to 4 percent solids, the waste can be handled with
irrigation or flushing equipment.
-
The volumes of manure produced by a dairy animal:
| Cow size |
Daily gal. |
Cu. Ft. |
Yearly gal. |
Cu. Ft. |
| 1000# |
10 |
1.33 |
3650 |
486.6 |
| 1500# |
15 |
2 |
5475 |
730.0 |
Quantity of nutrients produced by a dairy animal (pounds)
| Cow Size |
N |
P |
K |
$ |
| 1000# |
150 |
27 |
99 (yearly) |
|
| 1500# |
223 |
40 |
149 |
|
NUTRIENT VALUE OF DAIRY MANURE/CROPS FED
A third way to consider the value of manure...The
University of Wisconsin publications place the nutrient value of manure at
75% of the nutrient value of the crops fed to dairy animals. The
same study finds that with "manure disposal methods" found on most farms,
less than 30 percent finds its way back to the field.
7. Tie stall barn manure is equivalent to freestall
manure as far as starting moisture content.
8. When evaluating moisture content of given
operation, consider
a. bedding
b. amount
of drying that takes place: freezing, hot sun and wind.
9. Consider
time of year when viewing "present" conditions. Things can change.
Determine accurate bedding amounts and types during winter and summer.
10.
Understand sand and barn line.
a. higher
liquid, the more dangerous
11. It is
difficult to thaw frozen materials.
Heat of fusion-80
calories/gram of ice
One calorie-heat
required to raise temperature of one gram water one degree Celsius.
Once ice melts to
a liquid at 32 degrees F, the same amount of heat will raise the
temperature of that gram of water 80 degree C., or 144 degrees F,
resulting in a sample at 144 degrees + 32 degrees = 176 degrees.
12. The
total percent's of liquid and solids must be 100 percent. If a
sample tests 88 percent liquid, it has 12 percent solids, etc.
13. Cutting
the percentage of solids in half, requires adding an equal volume of water
to the original quantity.
by volume:
10 gallons of 12% solids or 88% moisture
+10 gallons of 0% solids
20 gallons of 6% solids or 94% moisture
14.
Converting a pound of bedding to liquid condition requires a gallon of
water. A fifty pound bale of straw requires 50 gallons of water.
15. Manure
varies from farm to farm and depends upon:
a.
feeding -haylage, corn silage, pasture, high roughage, low roughage.
b.
barn environment - freezing, evaporation, density of livestock.
c.
production - higher production yields more manure and generally
higher moisture content.
The previous
items: Manure Quantities, nutrients and relevant items, and Nutrient
Value of Dairy Manure/Crops fed are reproduced with permission from:
MWPS - 18
Livestock Waste Facilities Handbook, Midwest Plan Service, Ames IA 50011
|
