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There has been a flurry of biochar mentions in the past few days due to a small mention in TIME. Philip Small at NSCSS notes a fuller profile of a producer mentioned in the TIME article.
Josh [Frye] set out to procure his own gasifier. He worked with Southern Illinois-based Coaltec Energy to identify a technology that best met his needs, and settled on the fixed bed gasifier produced by Westside Energies of Canada. Coaltec is the US sales representative for Westside Energies, and the companies helped him apply for grants to purchase and install the approximately $1,000,000 unit.My first reaction was that this isn't a viable biochar system. It wouldn't have happened without subsidies. Frye wouldn't even be in the chicken business without subsidies for maize since that is a primary ingredient for chicken feed.Things fell into place as grants and low-interest loans came through from several West Virginia state agencies such as the West Virginia Department of Agriculture who gave $15,000. After the grant writing was completed, the price of metal suddenly spiked, increasing the cost of the gasifier. Westside and Coaltec kicked in a contribution to keep the project within budget.
A more welcome surprise came for Josh when he was introduced to the concept of biochar by Tom Basden, an extension specialist in nutrient management at West Virginia University. “Tom told me I would end up growing chickens mainly for the poop,” Josh said. “I thought he was off his rocker, but now I think he might be right on the money.”
Josh is now producing a high quality biochar and has sold his first ton at a net price of $480 ($600 a ton for the char and $120 a ton transport costs) to a farmer in New Jersey who is testing its qualities for his crop of corn and soybeans. A farm in South Carolina is testing the char on pharmaceutical grapes (used in the nutritional supplement industry). Josh worked with IBI board members Johannes Lehmann and Stephen Joseph to optimize the gasifier to produce quality biochar rich in phosphorous and potassium. His test burns so far have made biochar that ranges from 1.7 to 3.2 percent P and 5.4 to 9.6 percent K.
My second reaction was that this was a waste of chicken manure, a particularly rich fertilizer since chickens have poor digestive systems that allow lots of nutrients to pass through undigested. When spread on fields soil bacteria finish the job of breaking it down to plant available forms.
In the winter of 2007-08, Josh ran six test burns testing wet or dry litter with or without adding wood shavings or chips. He has run the gasifier in a continuous steady state mode for up to ten days. He has determined that one burn per cycle of broilers is ideal, with a continuous operation period of about three weeks to warm the poultry houses up to 90F for hatchlings, tapering off to 70F.It would have been cheaper to just give propane to Frye and better to continue using his chicken manure for fertilizer. Biochar is a good thing, but subsidies enable systems to be created and operated that would never exist if they had to actually pay for themselves, and distort agronomic decisions. I think that this discredits biochar, making it subject to the same sort of criticisms as other not-ready-for-use greenish ideas.The initial funding covered much of the installation and first year of operation. However, Josh has realized that to continue a viable operation, he needs to have a structure to store and dry the chicken litter. Wet litter significantly slowed the process and was less efficient. Josh has received additional grant funding through MicroUnity to build a storage area. This storage unit should be completed in time for the 2008 fall/winter heating season.
Last year’s test burns produced about 30 tons of biochar and saved Josh about four thousand gallons of propane. Eventually he expects to reduce his propane consumption by 80 to 90 percent. He is also looking into using the gasifier heat in the summer to operate a chiller to cool the poultry houses. Josh Frye is happy with the unit and appreciative of all the help he has received from Coaltec and others.
In my view Lehmann has repeatedly shown bad judgement, associating himself with unwise projects in his efforts to promote biochar. Biochar needs a wise champion, someone who sees its value and uses, and will support projects that show it in good light. For example, the same type of demonstration system that took problem materials that have few uses - such as orchard and vineyard prunings, or forest slash - would be compelling. The Danish system mentioned in Energy Mates uses old wooden packing crates.
It is interesting that some of the research about biochar done in S. America found that biochar was particularly beneficial when coupled with chicken manure, not made from it. The manure provided nutrients and the biochar helped make good use of them.
GJ: My first reaction was that this isn't a viable biochar system. It wouldn't have happened without subsidies. Frye wouldn't even be in the chicken business without subsidies for maize since that is a primary ingredient for chicken feed.
PS: It should pencil out as a replacement for propane, as it turns the manure from a waste disposal cost element into an alternative fuel. I suppose it is just a question of how long you need to amortize the equipment cost to achieve a competitive ROI. I assume it is positive, but you never know until you get out the calculator. OTOH, the market price of $600/ton for the char mentioned in the article is um likely more conceptual than actual.
GJ: My second reaction was that this was a waste of chicken manure, a particularly rich fertilizer since chickens have poor digestive systems that allow lots of nutrients to pass through undigested. When spread on fields soil bacteria finish the job of breaking it down to plant available forms.
PS: True, but if the manure is building up b/c the local demand isn't there, that is not workable. The sweet combination is to make char from only as much manure as can't be distributed as nutrient rich fertilizer and mix that char with chicken manure: the mix is worth more than the sum of the parts.
GJ: It would have been cheaper to just give propane to Frye and better to continue using his chicken manure for fertilizer. Biochar is a good thing, but subsidies enable systems to be created and operated that would never exist if they had to actually pay for themselves, and distort agronomic decisions. I think that this discredits biochar, making it subject to the same sort of criticisms as other not-ready-for-use greenish ideas.
PS: A few subsidies in the front end, to prime public perception is a good thing. But permanent and generous subsidization is dangerous and damages the long term potential of the solution, biochar in this case. When a problem owner sees a problem as worth more as an attractant of funding than the value of solving the problem, all sorts of perversity results. Yech.
GJ: In my view Lehmann has repeatedly shown bad judgement, associating himself with unwise projects in his efforts to promote biochar. Biochar needs a wise champion, someone who sees its value and uses, and will support projects that show it in good light. For example, the same type of demonstration system that took problem materials that have few uses - such as orchard and vineyard prunings, or forest slash - would be compelling. The Danish system mentioned in Energy Mates uses old wooden packing crates.
PS: I can see that. In his defense, Johannes is learning from his mistakes, as we all are. I am now a little skeptical of using forest slash, unless it is to convert forest to pasture. The large scale Canadian forest biochar proposal in 2007 was poorly conceived from the start, and then the Wardle study came out in 2008 showing that biochar stimulates the decomposition of forest litter. That's a positive feature if you are using biochar to goose your compost, not so great for maintaining forest litter, and few have promoted a forest slash proposal since.
GJ: It is interesting that some of the research about biochar done in S. America found that biochar was particularly beneficial when coupled with chicken manure, not made from it. The manure provided nutrients and the biochar helped make good use of them.
PS: The combination of biochar plus chicken manure is working wonders on my 8 cu yd leaf pile right now. I used only 0.25% volume:volume char+manure. There is ice on the tarp, but underneath its 60 degrees and steaming away. Normally the pile just sits there cold and wet, a static pile waiting for spring to be fed into the compost-proper.
Posted by: Philip Small at December 6, 2008 08:41 AMCan you point me to more about the Canadian forest slash proposal? Was anything actually done, did things go beyond the proposal stage?
I am influenced by my local situation. Huge quantities of forest slash, orchard and vineyard prunings and other woody materials are burned continuously.
I imagine diverting those streams to char production, doping it with dairy manure, and so make a significant improvement in ag lands while ameliorating some waste and emissions problems. It's not worth $480 a ton but I think that it would be a money spinner at a quarter of that, especially if clever use was made of coproducts such as in a CHP system or even using the off gases for chemical/fuel/fertilizer manufacturing.
In my view the price of biochar needs to be loosely comparable to other soil amendments such as manure and compost for growers to buy lots of it. Applying tons per acre to millions of acres, as would be required to have any of the imagined impacts, has to be affordable. There can still be a gardener market for bagged material that is hideously expensive on a per ton basis, but for commercial growers the price needs to be far lower.
I'm trying to interest some fellows who have the where with to do with in these schemes. If subsidized demonstration systems are to be useful for kick starting this industry then they need to be commercially viable demonstrations. In my view projects like Frye's do more harm than good since they do not actually demonstrate anything that could attract investors.
Posted by: back40 at December 6, 2008 09:54 AM