Slurry-Use Equipment

For the use of biogas slurry, a multitude of tools and technologies have been developed. They differ mainly according to the quantities of digested material. Big differences exist as well between developing and industrialized countries, depending on the technological development and the cost of labor. Slurry use technologies range from hand-application with the help of a bucket to mechanized distribution, supported by GPS (global positioning system) and a computer on board of the liquid manure spreader. The choice of technology essentially depends on the amount of slurry and the area to be fertilized as well as on the financial means and the opportunity cost of labor.

On small farms in developing countries, simple but effective tools are used. They include buckets, scoops, containers with straps, wooden wheelbarrows with lids, barrels on wheels and others. These tools allow a precise application of slurry. The most economic way to apply slurry is by means of gravity, either by a network of small slurry furrows or by mixing slurry in the irrigation system. Both options require a gradient of at least 1% (for irrigation water) and 2% (for slurry distribution), sloping from the biogas plant's overflow point to the fields.

Making best and least labor-intensive use of the slurry is an important planning parameter. Especially where gravity distribution is feasible, the positioning of the biogas plant and the expansion chamber and the level of the expansion chamber overflow are of high importance. In rather flat areas, it should be considered to raise both the stable and the biogas-plant in order to allow a slurry distribution by gravity.

Device for slurry distribution by tractor. Photo: Krämer (TBW)

In industrialized countries and for large plants in developing countries two methods of mechanized distribution systems have evolved:

Distribution via piping systems

The slurry is pumped directly from the slurry storage tank onto the field and is distributed there. If the pump is rather small and the pressure and transported amounts are low, the distribution can be done by hand. With increasing pressure and transported amounts, the distribution system is attached to a tractor. The tractor does not have to be very powerful as there is no need to pull a heavy tanker. The main advantage of this method is the low ground pressure and the ability to enter into fields of steep slope, of fragile soil structure and during bad weather.

The biogas slurry, if it is not too viscous, can be applied with a liquid manure rainer. The disadvantages are the costly pump and the expensive piping system. Therefore, this method is only economic for fields close to the slurry storage container.

Distribution via tanker

The tanker is filled at the slurry storage and pulled to the field for distribution. Below are the principal distribution systems ex-tanker:

With reflection plate

The slurry is squirted through a nozzle against a reflection plate which, by it's special form, diverts and broadens the squirt. An improvement of the simple reflection-plate-distribution is a swiveling plate which leads to a more even distribution.

Direct application through sliding hoses

The slurry is pumped into a distribution system which feeds a number of hoses which move closely to the ground. The slurry is applied directly on the soil surface, therefore reducing nutrient losses. Distances between the hoses can be adjusted to suit different plant cultures.

Hoses with drill coulters

The soil is opened with two disks (drill coulters) in a v-shape. The slurry is applied with sliding hoses into the v-furrows, which are closed behind the hose. This application method could be labeled 'sub-surface application'. It is the most advanced in terms of avoiding nutrient losses. Similar to the hose application, distances between application rows are adjustable. Alternatively to the hose application, the slurry can be positioned by a metal injector.

The application methods close to the soil surface, in contrast to the broadcasting methods, have the advantage of a higher degree of exactness and less nutrient losses to the atmosphere. Fertilization can be better adjusted to plant needs. In contrast to broadcast-spraying, direct application is possible even at later stages of plant growth without damaging the leaves. Disadvantages are the rather sophisticated machinery necessary and the high costs involved. Direct application methods are, therefore, mostly used as inter-farm operation.

Separation of slurry and drying of the moist sludge

In industrialized countries, the slurry is usually separated by means of separators and sieves. The water is re-fed into the digestion process or distributed as liquid manure while the moist sludge is dried or composted. As a simple technology for separation, slow sand-filters can be used.

The moist sludge can be heaped on drying beds, filled in flat pits or simply placed on paved surfaces near the biogas plant for drying. Depending on climatic conditions, large drying areas may be necessary. Drying times and nutrient losses can be reduced by mixing dry substances with the moist sludge. A disadvantage of all drying methods, again depending on the climate, is the high loss of nutrients. In particular heavy rains can wash out the soluble nutrients. Losses of nitrogen, for example, can amount to 50% of the overall nitrogen and up to 90% of the mineral nitrogen. Drying of the moist sludge can only be recommended where long distances and difficult terrain hampers transport to the fields or if composting is difficult for lack of manpower and lack of dry biomass.

Composting of slurry

Dry plant material is heaped in rows and the liquid slurry is poured over the rows. Ideally, plant material and slurry are mixed. The mixing ration depends on the dry matter content of plant material and slurry. The main advantage is the low nutrient loss. Compost, containing plant nutrients in a mainly biologically fixed form, is a fertilizer with long-term effects. It's value for improving soil structure is an additional positive effect of importance.

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