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The above image is typical of concentrated animal feeding operations (CAFO) which have many issues relative to the environment, particularly manure management. Compounding those issues is the growth of CAFOs as shown in the chart below which shows the magnitude of growth of the CAFOs versus the smaller farms and hence the issues of manure management accompanying that growth.

CAFO Growth Chart 2

Ammonia Saturated Lands Inhibit Expansion

Because groundwater and surface water are closely linked, water pollution from CAFOs can affect both sources if one or the other is contaminated. Surface water may be polluted by CAFO waste through the runoff of nutrients, organics, and pathogens from fields and storage. Waste can be transmitted to groundwater through the leaching of pollutants. Some facility designs, such as lagoons, can reduce the risk of groundwater contamination, but the microbial pathogens from animal waste may still pollute surface and groundwater, causing adverse effects on wildlife and human health.

Spain’s swine industry is typical of many CAFOs both throughout the world and with all animals grown for food. For Spain, the world’s fourth largest pork producer behind China, the USA and Germany, this comes at a time when they want to double or triple their production capacity. With a major swine flu epidemic sweeping China’s pig farms and production shifting from colder climes, demand for increased production in Spain’s swine farming sector is at an all-time high. Most farm operators have plans to double or even triple hog farming in the next year alone. 

However, they are hindered by ammonia saturated lands from a history of irrigating their fields with manure effluent. Strict EU imitations on the amount of ammonia effectively limits the amount of manure generated and therefore the number of swine that can be grown.  Most CAFOs in developed countries are also now governed by regulations that restrict how much manure waste can be distributed and the required quality of the materials.

Depuporc estimates that their proprietary system could limit annual nitrogen production by hog farms to 16 kilos per hectare, less that one-tenth the limit of 210 kilos per hectare per year that was established by Spain’s Royal Decree 324/2000.

Until now, the best solution was to store manure wastewater in lagoons and periodically pump out the water.  The high solids content water would then be screened, clogging filters and membranes, and used as the irrigation water.  However, this process did not remove the ammonia and other undesirable dissolved contaminants.  The solids were pressed into a cake. That is both environmentally irresponsible and expensive to farm operators.

The best solution is to treat the manure and manure waste water “on-line” beginning with a screening process, then a coagulation/flocculation process to remove all suspended solids and finally an advanced oxidation stage to remove the dissolved contaminants, such as ammonia.

A Robust Technology Solution

In March of 2017, Spain’s Depuporc entered into a licensing agreement with OriginClear to incorporate our Electro Water Separation™ (EWS) and Advanced Oxidation™ (AOx) technologies into their patented swine manure wastewater treatment system. OriginClear’s EWS+AOx were determined to be ideal final stage for clarifying the flow of manure water and removing the ammonia.

A commercial pilot was launched to prove to Spanish pork producers the workability of the method and also demonstrate the potential breadth of this ground-breaking technology in action. Depuporc has succeeded in building a complete system that can continuously transform pig manure into a zero-waste output of fertilizer and clean essentially ammonia free irrigation water.

 

Eduardo Chopo Co-Owner of DepuporcEduardo Chopo Fraguas of Depuporc

Major Barrier To Expansion Solved

“Their only solution is to treat the manure for fertilizer and water reuse,” said Eduardo Chopo, co-owner of Depuporc . “This is where our patented system, which incorporates OriginClear’s technology as a third and final step, has been shown to reduce pollutants and also generate valuable fertilizer and irrigation-grade water, solving a major barrier to expansion for these producers.”

Portable Point-Of-Use, Onsite Systems

Depuporc’s 30 metric ton per day mobile treatment systems can travel to the hundreds of farms in Spain to prove the process and show the farmers how to process their lagoons into profitable and "clean" manure cake and clean water for use in cleaning and other farming chores. As can be seen in the Product Line chart on below, Depuporc’s standard offering scales up to 400 metric tons per day.

Depuporc Plant translated caption
Depuporc's system, which incorporates OriginClear’s advanced water treatment technologies, has been selected as one of 101 Spanish inventions to be presented at the upcoming United Nations Climate Change Conference in Madrid!

Depuporc Process - In Sequence

The patented Depuporc process incorporating OriginClear’s EWS and AOx technology takes place in several stages with separate holding tanks.

  • The manure and waste water flows or is transported from the farm to the first stage holding tank
  • In the first stage holding tank the manure is homogenized with agitators and chopper pumps
  • The manure water is then pumped to a vertical screw press separator with a compacting module where gross separation of the solid manure particles from the manure water is accomplished and relatively dry manure to discharged and manure water is sent to a second stage holding tank
  • From the second stage holding tank, the manure water is pumped to a self-cleaning micro-filter where manure laden water is recycled to the second holding tank and cleaner manure water is sent to a third holding tank
  • From the third holding tank, the manure water is pumped to sludge thickener where the water is pumped to the OriginClear Electro Water Separation (EWS) tank
  • The EWS tank’s electrochemistry process coagulates the smallest particles of manure and floats them to the surface for separation. At this stage, the manure water is essentially free of all suspended solids
  • The water is then pumped into the OriginClear Advance Oxidation (AOx) tank where extensive electrode racks generate oxidizing agents such as, Reactive Oxygen Species (ROS): hydroxyl radicals, ozone & hydrogen peroxide and Multiple Oxidizing Species (MOS): hypochlorous acid & chlorine
  • The water is then pumped to the final effluent tank for reuse of the water or irrigation.
  • Manure laden water requires multiple stages of solid – liquid separation to remove essentially all suspended solids. Without the removal of the suspended solids, the oxidizing agents generated in OriginClear’s Advanced Oxidation stage would oxidize the suspended solids rather than oxidize the dissolved organics, such as ammonia
  • Depuporc reports the following specifications for the demonstration system: 30 m3/day treatment capacity, supplying 6.4 tons/day of solids with 89% organics for fertilizer, and ability to recycle 11,000 tons/year of water for irrigation or farm cleaning. The system draws 38kW, which can be supplied by the farm’s solar array, when conditions permit
(Click Image for Video of System)

Depuporc System Collage

Depuporc/OriginClear Solution Performance

Water Analysis

Depuporc System Chart 2-1


Product Line/Cost Analysis

DEPUPORC S.L.

Oficina: Zaragoza - 50015
Fabrica: Cadrete - 50420

 ingenieria@depuporc.com
www.depuporc.com

SISTEMA "DEPUPORC": DIMENSIONADO DE PLANTAS
"DEPUPORC" SYSTEM: WASTEWATER TREATMENT PLANTS SIZE

Depuporc Logo
Tamaño/Size (m3/dia) dpp36 dpp60 dpp120 dpp200 dpp400
Capacidad/Capacity (m3/h) 1.5 2.5 5 8 16
Capacidad/Capacity (l/min) 25 42 83 133 266

Potentia Electrica Instalada (kW)

Total Power (kW)

29.68 45.69 100.01 166.42 322.00

Coste Consumo Electrico (€/m3)
Cost Assuming (€/m3)

1.98 1.78 1.78 1.78 3.55
(2) Consumo calculado para 60 minutos de tratamiento. 60 minutes EWS+AOx treatment
Coste Dosificacion Quimica (€/m3)
Chemical Dose Cost (€/m3) 
0.30 0.30 0.30 0.30 0.30
(3) Consumo calculado para 60 minutos de tratamiento. 60 minutes EWS+AOx treatment

Costes Estimados Mantenimiento (€/m3/año)
Labor Cost (€/ton/year)

0.25 0.25 0.22 0.22 0.20
(4) Se analizara en cada caso en concreto las tareas del mantenimiento que puede realizar el cliente para optimizar este coste (In each case, the maintenance tasks that the client can perform to optimize costs are analyzed)
Sustitucion de reactores (€/m3)
Reactors replacement (€/m3)
0.29 0.20 0.15 0.13 o.13
(5) Estimados una vida media de 3 años. 3 years useful life


Focus On Animal Welfare 

Spain’s swine production industry is very focused on animal welfare because it increases productivity. For example, with better conditions, piglet births can go from 30 to 34 per year, for each mother pig, or sow, a 13% increase in productivity. The dominant factors required to accomplish such an increase are feed regulation and quality, as well as animal drinking and cleaning water quality which not only improve animal hygiene and enable animal disease control, but also reduce water costs through reuse. OriginClear’s advanced water treatment technologies in this case, were proven to be the decisive game-changer. 

Depuporc Presentation Aragon-SpainThe Europeans are leading with these animal welfare and water treatment technologies.

Conclusion

Proper management of manure wastewater is essential not only to swine farming, but to the farming of other food animals:  cattle, diary, sheep and poultry.  All have the similar issues and must treat the manure for productivity and the environment.  In Spain, Depuporc and OriginClear have proven that their patented system is a cost effective and environmental solution.

View Our Modular Agriculture Wastewater Treatment Products HERE

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