Energy Use in Swine Production
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1 Energy Use in Swine Production 53 rd Annual Midwest Rural Energy Council Bloomington, MN Feb 19-20, 2015 Larry D Jacobson Professor and Extension Engineer U of MN, St. Paul, MN
2 Energy Use in Swine Production Direct (Fossil Fuel) Energy Primarily Propane and Electricity 2 to 5% of pig production cost (U of MN Farm Financial Management) Indirect (Feed) Energy Feed efficiency, rate of gain Estimated to be 60 to 70 % of pig production costs
3 Economic Energy Impact significant for Contract Growers Due to business model used in modern production system (integrators/contract growers), fossil fuel energy represent a higher % of the out of pocket cost for the contract grower than the reported 2 to 5 % for producing a pig from birth to slaughter.
4 Present Cost of Fossil Fuel Energy Electricity Average Midwest $0.10 /kwh Variable costs due to location and generation source, plus demand-side programs available Propane Average Midwest $1.50/gal Highly volatile costs due to demand / location Diesel (off road) Average estimate in US = $2.50/gal Much less volatile costs than propane or electricity Jay Harmon, Iowa State Univ.
5 Areas of Energy Usage Electrical Ventilation exhaust fans plus mixing fans and curtain controllers in natural ventilation barns Creep heat for young piglets Lighting in buildings Power Washing - disinfecting surfaces Feed and Water delivery
6 Electrical Areas of Energy Usage Ventilation fans- even if natural ventilation some electrical energy needed for control
7 Areas of Energy Usage Electrical Creep heat for young piglets Lighting LED lights
8 Smaller uses of electrical energy Feed and Water delivery
9 Areas of Energy Usage Propane or Natural Gas Space heating to maintain room temps Creep heating for surface temp control Water heating for cleaning and washing Incineration for mortality disposal
10 Areas of Energy Usage Propane or Natural Gas Space heating to maintain room temps Radiant heaters for zone heating Radiant heater Space heater
11 Midwestern Pig Finishing Barns 90+% are either CS or TV with Deep Pits Curtain Sided (CS) Tunnel Ventilated (TV)
12 Annual Electrical & Propane Energy Use for 2400 head Tunnel Ventilated, wean-to-finish barn (MN) Bill Crawford, PCM, Fairmont, MN Useage $ $/unit kwh- Propane Gal / pig space 2010 Elect kwh 65,000 5, Propane Gal 5,115 7, Elect kwh 68,740 5, Propane Gal 4,344 7, Elect kwh 72,760 6, Propane Gal 4,915 7, Elect kwh 70,040 6, Propane Gal 5,450 9,
13 AVERAGE Annual Electrical & Propane Energy Use for Various Swine Finishing Facilities in Iowa* Type of Barn kwh/ pig space Propane, gal/ pig space # of Barns Years of data Hybrid (fans with side wall curtains) Tunnel, growto-finish Tunnel, weanto-finish to 5 years year to 2.9 years *Hanna, Harmon, & Schweitzer, 2014 (ASABE)
14 Areas of Energy Usage Diesel Fuel Use Backup Generators Use of skid-steer, front end tractor loaders, trucks to transport feed and pigs Tractors/trucks to load and spread manure
15 Diesel powered Backup Generator
16 Estimated Energy Usage of 3000 sow operation
17 Electrical Energy Usage of 3000 sow operation Operating Ventilation Exhaust Fans in winter and summer
18 Electrical Energy Usage of 3000 Heat Mats and Lamps in farrowing crates sow operation Osborne Industries photo
19 Options for creep heaters Conventional 250 watt heat lamps Energy Efficient 175 watt heat lamps Electric heating mats with temp. control Propane or Natural Gas fired radiant heater with temperature control
20 Electrical Energy Usage of 3000 sow operation Fluorescent lights Lighting
21 Comparison of various lighting options in livestock housing Lamp Type Power use in watts Light output in lumens Lumens/ watts Lamp or bulb life in hours Cost per lamp or bulb Incandescent 100 1, $1.20 Halogen 72 1, ,000 $1.75 Compact Fluorescent (CFL) 26 1, ,000 $6.50 Light Emitting 22 1, ,000 $55.00 Diodes (LED) screw-in 4-ft T8 68 5, ,000 $3.50 fluorescent 4-ft LED tube 46 4, ,000 $70.00 From Lighting Technology: LED Lamps for Home, Farm, & Small Business; Scott Sanford, UW Madison July 2014
22 Estimated Annual Energy Usage of 3000 sow operation Electrical Energy Ventilation fans 250,000 kwh (winter 70,000 kwh; summer 180,000 kwh) Creep Heat 250,000 kwh (use of 125 watt heat lamps in farrowing) Lighting 170,000 kwh (gestation 110,000; farrowing 60,000)
23 Estimated Annual Energy Usage of 3000 sow operation Power Washing 10,000 kwh (20 hours of washing per week) Feed & Water delivery 5,000 kwh Electrical Subtotal 685,000 kwh
24 Estimated Annual Energy Usage of 3000 sow operation Space Heating with Propane fired units
25 Estimated Annual Energy Usage of 3000 sow operation Propane Usage Space Heating 3 billion BTUs (33,000 gal of Propane) Water Heating 300 million BTUs (3,500 gal of Propane or 90,000 kwh) Propane Subtotal 37,000 gals
26 Estimated Annual Energy Usage of 3000 sow operation Total Estimated Electrical Energy Usage 700,000 kwh or 230 kwh/sow space Total Estimated Propane Energy Usage 37,000 gals or 12.3 gals/sow space
27 Control Direct Energy Costs Heated buildings in cold/cool weather Precise control of ventilation rates Exhaust Fan efficiency Building Insulation and leaks Environmental Controllers (e.g. temperature setpoints and heater on-off time)
28 BESS Laboratory s Ag Ventilation Fan Handbook to order Or access fan data online at:
29 0.25 Exhaust Fan Test Data Static pressure Speed Airflow Efficiency in. H 2 O rpm cfm cfm/w ,642 2, ,638 2, ,635 1, , , BESS Lab
30 Energy Efficient Exhaust Fans High CFM/watt rating for fans (especially for fans that run a greater percentage of the time)
31 All 24 exhaust fans are not the same! Airflow Efficiency 0.10 In. H 2 O cfm/w Fan 1 7, Fan 2 7, Fan 3 6, Fan 4 4,
32 Fan Selection Matters H 2 O (5,000 hrs per year) Most efficient (Fan # 2) 16.6 cfm/w, 7000 cfm $211 per $0.10 /KwH Less efficient (Fan # 1) 12.4 cfm/w, 7,270 cfm $293 per $0.10 /KwH Jay Harmon, Iowa State Univ.
33 Large Exhaust Fans Belt Driven
34 In place Air Flow measurement of Belt-Driven Fans
35 Belt-Driven Exhaust Fan Maintenance Airflow (cfm) 25,000 20,000 15,000 BESS lab Airflow before belt adj. Airflow after belt adj. 10,000 5, Static pressure (Pa) 60
36 Ventilation Exhaust Fan Maintenance Dirty/Dusty fan shutters and grills can result in up to 40% reductions in airflow rates
37 Ventilation Exhaust Fan Attachments also important Comparison of 24 fans 8,000 Shutter & guard only + Wind hood Airflow (cfm) 7,000 6,000 + Discharge cone 5,000 Wind hoods 4, Static pressure (in. of water) 0.30 Discharge cones Source: BESS Lab data
38 Nursery example to show importance of ventilation on Propane use Estimated Propane 995 gallons/yr $2,000 /yr 1000 Head Nursery 41 by 84 R 11 in Walls R 30 in Ceiling 2.5 cfm airflow/hd minimum 76 F average Room Temp $2.00/gallon of propane Jay Harmon, Iowa State Univ.
39 Fuel Cost comparison Average Barn Temp Gallons LP Annual Cost Difference from Base 72 F 712 gal $1,424 - $ F 837 gal $1,674 - $ F 995 gal $2,000 Base 78 F 1154 gal $2,308 + $ F 1361 gal $2,722 + $722 Jay Harmon, Iowa State Univ.
40 Use of Radiant Heater so can operate lower barn air temperatures Radiant heaters heat surface without direct heating the air Radiant Heaters Less expensive to zone heat (surface temp of 80+ F) rather than heat the entire building (room temp maybe 70 F) Jay Harmon, Iowa State Univ.
41 Adding Insulation?? Does it pay? Recommendation for Midwest (MWPS) R 33 in ceiling R 20 in walls Perimeter Insulation (R 6.5) Jay Harmon, Iowa State Univ.
42 Adding Insulation?? Improving from R 30 to R 40 in ceiling Example savings of $94 per year Improving from R 10 to R 30 in ceiling Example savings of $782 per year Adding Insulation is most beneficial when it is poorly insulated. Making good insulation better rarely pays. Jay Harmon, Iowa State Univ.
43 Uninsulated Concrete Kneewall 70 F Room 6 inch 0 F Outdoors Concrete 34 F Surface Condensation occurs above 25 % RH R= 1.33 Heat Flow
44 Insulated Concrete Kneewall 6 inch 70 F Room Concrete 0 F Outdoors + 1 inch Rigid insulation 62 F Surface Condensation only R= 6.33 occurs above 75% RH Heat Flow
45 Sealing Curtain Openings Mike Brumm, Brumm Consultancy Inc.
46 Bubble wrap insulation for winter Mike Brumm, Brumm Consultancy Inc.
47 Controllers
48 Set-Point Temperature Target temperature for controller NOT the average room temperature Other controller settings are based on set-point temperature Temp. Room T Set point
49 2 Variable-Speed Fans & 2 Single-Speed Fans Airflow rate Stage 4 Stage 3 6 Stage Stage Minimum 1 Temperature Bandwidth 1 Offset Bandwidth Differential 3 Differential 4 Set Point Jay Harmon, Iowa State Univ.
50 Heat output Heater Control Heater Off Heater On Continues Heating to X Degrees??? Differential Heater Offset Set Point Temperature Jay Harmon, Iowa State Univ.
51 Heater offset of at least 1.5 F helps to Prevent Heater Overshoot
52 6/9/04 - J. Harmon Setpoint = 70 F Furnace on at 69 F and off at 70 F VS Fans increase at 70.5 F Mike Brumm, Brumm Consultancy Inc. Recommendation: Furnace on at 67 & off at 68.5 VS Fans increase at 72 F Slide courtesy : Eric Christianson, Christensen Farms
53 Blue Valve reduces heater output to 65% of maximum Mike Brumm, Brumm Consultancy Inc.
54 Questions??
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