{"id":910,"date":"2017-08-05T08:24:57","date_gmt":"2017-08-05T15:24:57","guid":{"rendered":"http:\/\/rccostello.com\/wordpress\/?p=910"},"modified":"2026-05-08T03:10:03","modified_gmt":"2026-05-08T10:10:03","slug":"biogas-production-dairy-cattle-manure","status":"publish","type":"post","link":"https:\/\/www.rccostello.com\/wordpress\/biogas\/biogas-production-dairy-cattle-manure\/","title":{"rendered":"Biogas Production from Dairy Cattle Manure"},"content":{"rendered":"<figure id=\"attachment_951\" aria-describedby=\"caption-attachment-951\" style=\"width: 4662px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-951 size-full\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1.jpg\" alt=\"Each of eight biogas digesters are 1,000,000 gallons\" width=\"4662\" height=\"3288\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1.jpg 4662w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1-300x212.jpg 300w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1-768x542.jpg 768w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-1-1024x722.jpg 1024w\" sizes=\"auto, (max-width: 4662px) 100vw, 4662px\" \/><\/a><figcaption id=\"caption-attachment-951\" class=\"wp-caption-text\">The Digestors at the Biogas Plant in Stephenville, Texas<\/figcaption><\/figure>\n<figure id=\"attachment_953\" aria-describedby=\"caption-attachment-953\" style=\"width: 2319px\" class=\"wp-caption aligncenter\"><a href=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-953 size-full\" src=\"http:\/\/rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4.jpg\" alt=\"The low pressure compressor is a lobe type and the high pressure compressor is a reciprocating type\" width=\"2319\" height=\"1375\" srcset=\"https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4.jpg 2319w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4-300x178.jpg 300w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4-768x455.jpg 768w, https:\/\/www.rccostello.com\/wordpress\/wp-content\/uploads\/2017\/08\/Huckabay-plant-4-1024x607.jpg 1024w\" sizes=\"auto, (max-width: 2319px) 100vw, 2319px\" \/><\/a><figcaption id=\"caption-attachment-953\" class=\"wp-caption-text\">The Amine unit, the Glycol unit and the Compressors at Stephenville, Texas Biogas Plant<\/figcaption><\/figure>\n<p>In 2007, COSTELLO provided engineering services to the Microgy biogas plant in Stephenville, Texas. This plant was the largest plant in the United States to produce pipeline grade biomethane from&nbsp;dairy cow manure.<\/p>\n<p>The Microgy plant converted dairy cow manure and other organic matter into biogas using an anaerobic process. The bacteria were thermophilic. &nbsp;The biogas produced was treated and converted to biomethane that was injected into the natural gas sales pipeline.<\/p>\n<p>Incoming manure from neighboring dairies and other organic matter was treated in eight digesters. A heater in each digester maintained temperatures in the digesters to allow for optimum production of biogas. This biogas was composed of 60% methane (CH<sub>4<\/sub>), 40% carbon dioxide (CO<sub>2<\/sub>) and trace amounts of other gases including hydrogen sulfide (H<sub>2<\/sub>S). These produced gases exited the digesters through a compressor that provided a draft on the eight digesters. The biogas flowed to an amine unit and a multi stage reciprocating compression system.&nbsp;The amine unit removed almost all of the H<sub>2<\/sub>S and CO<sub>2<\/sub>. &nbsp;The gas was then dehydrated in a glycol unit before finally entering the natural gas sales pipeline.<\/p>\n<p>Reject gases from the amine unit,&nbsp;H<sub>2<\/sub>S and CO<sub>2<\/sub>, were directed to a biofilter that converted the&nbsp;H<sub>2<\/sub>S to weak sulfuric acid and the CO<sub>2&nbsp;<\/sub>was emitted to the air.<\/p>\n<p>The effluent in the digesters was discharged from the digesters per requirements of the Wastewater Division in Texas. A flare was an integral part of the entire system to burn off gases in emergency situations such as when the downstream upgrading system was inoperative but the digesters were still producing gas.<\/p>\n<p>Later on, COSTELLO designed a system to take waste heat from the <a href=\"http:\/\/www.rccostello.com\/skid_mounted_plant.html\">modular<\/a> amine unit and supply this to the digesters to maintain the temperature of the digesters in the winter time.<\/p>\n<p>The&nbsp;digesters were supplemented with waste glycerin from a local biodiesel plant.<\/p>\n<p>The plant was eventually sold to Element Markets, in Houston. As the price of natural gas dropped the biogas plant became uneconomic to operate. &nbsp;It was eventually shut down and the equipment auctioned off.<\/p>\n<p>This was a sad day for renewal energy because the engineering effort and money put into the project was lost. However, thinking minds have changed since a decade ago and&nbsp;<a href=\"http:\/\/www.rccostello.com\/biogas.html\">COSTELLO<\/a> retains the knowledge gained on this project that can help you with your Biogas plant.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>In 2007, COSTELLO provided engineering services to the Microgy biogas plant in Stephenville, Texas. This plant was the largest plant in the United States to produce pipeline grade biomethane from&nbsp;dairy cow manure. The Microgy plant converted dairy cow manure and other organic matter into biogas using an anaerobic process. The bacteria were thermophilic. &nbsp;The biogas [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[3,1],"tags":[],"class_list":["post-910","post","type-post","status-publish","format-standard","category-biogas","category-modular-plants","entry","has-post-thumbnail"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Biogas Production from Dairy Cattle Manure &#8211; COSTELLO<\/title>\n<meta name=\"description\" content=\"Biogas Production-Incoming manure from neighboring dairies was treated in eight digesters. Heat from the amine unit maintained temperatures in the digestors\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.rccostello.com\/wordpress\/biogas\/biogas-production-dairy-cattle-manure\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Biogas Production from Dairy Cattle Manure &#8211; COSTELLO\" \/>\n<meta property=\"og:description\" content=\"Biogas Production-Incoming manure from neighboring dairies was treated in eight digesters. 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