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waste heat for use in other essential farm operations.

Initially, the farm had used anaerobic lagoons to break down, process and treat the waste. Recently, the lagoons were replaced with a new, two-stage biogas digester that improves the quality of treated waste. One of the primary byproducts of the process is digester gas, with a composition of about 60% methane and 40% carbon dioxide.

At present, the power plant is operating at full rated load. Forty percent of the electricity it generates supplies all of the farm’s electrical needs, including powering the mill that processes pel-letized feed for the animals and a cool cell ventilation system for the barns. The excess electrical output is sold to the grid, an additional benefit for the owners in a country with some of the highest electricity costs in the region.

The farm maximizes the engine’s effi-
ciency by utilizing the hot water recov-
ered from the engine jacket and high-
temperature intercooler circuits to sup-
ply heat where needed. About 30% of
the hot water is circulated through
plates in the floor of the building,
which houses newborn piglets, to pro-
vide consistent heat. This, in turn,
improves the young animals’ health
and reduces mortality among them.
Sixty percent of the heat goes to the
feed mill boiler, which produces steam
for the pelletizing process. Plant opera-
tors estimate that using engine heat
saves them about US$100/hr in energy
costs when the boiler is operating.
About 30% of the hot
water is circulated
through plates in the
floor of the building,
which houses newborn
piglets, to provide a con-
sistent heat. This, in turn,
improves the young ani-
mals’ health — reducing
the mortality rate.

The gen-set was supplied by Entec Services Ltd., Waukesha’s Auckland, New Zealand-based distributor. The gen-set was pre-packaged with a dump heat radiator, PLC controls, switchgear panel and heat recovery equipment in a modified 12 m shipping container for easy installation on-site. On-site, the plant required only a fuel gas source, electrical and water connections.