Haubenschild Farms Final Report - The Minnesota Project

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The Minnesota Project August 2002 expanding feedlot operations. He was also aware of the potential of anaerobic digesters to reduce these problems while at the same time producing energy and providing other benefits. The Opportunity In order to see if an anaerobic digester would work at his farm, Dennis submitted an application for consideration as an AgSTAR Charter Farm, and after completing a pre-feasibility assessment was one of 13 farms selected. AgSTAR is a national program, sponsored jointly by the Environmental Protection Agency, the Department of Energy and the Department of Agriculture. The Charter Farm Program was designed to facilitate demonstration of appropriate digester systems at various livestock farms. As a Charter Farm, AgSTAR provided Haubenschild Farms design and operational assistance in building their digester. AgSTAR contracted with RCM, a company with a proven track record of building successful on-farm digesters, to assist with the project. Mark Moser was the engineer, while RCM’s Richard Mattocks handled all onsite issues and helped to build the system. The Haubenschilds: Dennis, Bryan, Marsha and Tom (l to r) The farm also required a feedlot permit, including a manure management plan. The Minnesota Pollution Control Agency granted the permit. The digester qualified as manure storage, reducing the size of the storage pond required for storing digested manure. Even with this assistance, there were still barriers to be overcome, since traditional lending agencies in Minnesota are reluctant to provide the full financing for such projects, and Dennis needed help in securing financing. At this point the unique opportunities of the digester project at Haubenschild Farms were brought to the attention of several Minnesota governmental and non-profit agencies. The Onanegozie Resource Conservation and Development Council, The Minnesota Project, Minnesota Department of Commerce, Minnesota Office of Environmental Assistance, and Minnesota Department of Agriculture joined together to assist with the Haubenschild Farms project. These agencies saw the unique potential of manure digesters to mitigate negative environmental impacts while providing a source of renewable energy and promoting sustainable economic development. They agreed to help with the financing if the Haubenschild Farms project could be studied to determine its feasibility for other farms in Minnesota. 12
The Minnesota Project August 2002 Haubenschild Farms’ Goals for Installing a Digester The Haubenschilds have a long-term outlook on their farming operations. When looking at the expansion of their farming operations, they considered the future needs of the land and the impact of the increased operations on the environment. An anaerobic digester seemed to fit in well with their plans. Specifically, Haubenschild Farms wanted to design, build, start-up, and operate a digester with the following goals: 1. Increase the value of the manure for fertilizer. The sandy acres at Haubenschild Farms needs the addition of organic matter supplied by manure. By applying digested effluent to the fields instead of raw manure, the Haubenschilds expected to increase the useable nutrient value of the manure, and thereby phaseout the use of commercial starter fertilizer. At the same time, weed seeds and pathogens would be reduced. This fit the Haubenschild’s strong environmental ethic by reducing outside inputs to the land while returning value. 2. Reduce animal waste odor. An increase in herd size could bring a significant increase in odor and fly problems. This would not only create a more unpleasant work environment, but could also cause tension with neighbors and regulatory agencies. 3. Produce enough electricity and hot water to recover digester installation costs. 4. Produce enough hot water to offset propane use and supply heat for the barn in the winter. 5. Demonstrate the viability of an anaerobic digester system on an operating dairy farm in Minnesota. An anaerobic digester requires a manure handling method that is compatible with the operation of the system. A water flush system for collecting the manure makes it unsuitable for a plug-flow digester, because the manure slurry will become too diluted. Animal bedding systems using sand are also not appropriate for an anaerobic digester, due to sand build-up, which will eventually clog the system. 13 Haubenschild Family Farms Dennis’s father and mother, Don and Myrtle, started farming at the present location in 1952 with 160 acres and 10 cows. The farm is in the Green Lake watershed on the Anoka Sand Plain in southwestern Isanti County, about 40 miles north of the Twin Cities metropolitan area. In the early 1960s the family began to notice a decrease in organic matter content in their soils. They realized that by increasing manure use, they could improve soil tilth and reduce erosion potential. Dennis, who went to college and worked a number of years, returned to the farm with Marsha in 1972. By 1979 their milk herd numbered 80. Dennis had researched digesters while at college and was interested in alternative energy production. In the 1970s they installed a solar collector system for heating water for the dairy which is still functioning. They were milking 150 cows in 1998 when sons Tom and Bryan and their families wanted to farm with their parents and grandparents. The family decided that they should expand the dairy. When fully expanded they expect to use digested manure on all their crop acres for growing their 600+ acres of corn silage, 300 acres of alfalfa haylage, 30 acres of soybeans, and 40 acres of pasture. Freshening cows use the pasture. They purchase additional fresh hay to add to their total managed rations.
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