Farm and Family, Lansing, Mi, Price of Pellet Stove
Summary
Farm-based production of grass pellets for energy is an interesting new opportunity for farmers in the Northeast United states. Perennial grasses, such as switchgrass, can be grown on marginal land and made into biomass pellets on the farm. These pellets tin be used every bit heating fuel for homes and other purposes. This instance study analyzes the performance at Wood Crest Subcontract in Wapwallopen, Pennsylvania, where switchgrass is grown and pelletized. The analysis covers all aspects of the operation, from crop institution through marketing the crop, and provides a detailed analysis of costs every bit well as tips from the farmer on successful functioning.
Production of grass-based pellets has proved to exist challenging but feasible at Woods Crest Farm. It takes fourth dimension to learn how to abound, harvest, and pelletize switchgrass, and there are things about the crop that are different from traditional crops. After the ingather is harvested, pelletizing switchgrass successfully is a significant challenge, and many details must be carefully controlled if one is to produce pellets.
The total cost of production for pellets at Wood Crest Farm is $88 per ton. Nonetheless, labor costs are not included in this amount, equipment purchase costs are non accounted for, no profit is included, and land costs are only equal to the taxes due on the country. Space in the barn for operating the pelletizer is besides used without cost. Equally such, this represents a "bare bones" operating price. If these resources were not available, the cost of producing pellets would exist much higher. This highlights an of import point: the available resources at a farm can have a big impact on the viability of a pelleting operation.
Marketing is also a large challenge for grass pellets. The pellets are non suitable for nearly wood pellet stoves, and then information technology may take quite a fleck of attempt to develop a market for the product. In improver to pellets, Wood Crest Farm sells baled and ground switchgrass for a variety of uses as a way of diversifying its market place and increasing income.
This instance study describes the experiences of one farmer/pellet maker in the Northeast Usa, but information technology also serves equally a useful guide to others who may exist interested in trying something like.
Introduction
On-farm production of grass pellets is a relatively new opportunity for farm energy production in the Northeast United States. Some farmers take already taken the initiative to grow, harvest, and pelletize perennial grasses to either use on the subcontract or sell to others. The processes and equipment that were developed for wood pellets and feed pellets tin also be used to manufacture grass pellets, even at a smaller "farm scale." In the Northeast, many farms and homes use expensive fuel oil or other nonrenewable free energy sources for heat. There is a real opportunity for grass pellets to exist used instead, providing affordable, renewable heat to homes and businesses. Yet, the on-farm pelleting opportunity is still in its infancy, and very few people use them today as a fuel.
Many farms are well suited for producing grass pellets, especially those that have haying equipment and abandoned, marginal fields that are not suitable for food crops. In many parts of the Northeast Us, this is specially truthful given the shift away from grazing and the availability of degraded or low-quality country that is not suitable for food crop production. While hay equipment is widely available in the region and can be used to harvest and handle biomass grasses, specialized pelleting equipment is also needed, and the costs and the know-how related to those systems demand to exist understood in advance if farmers are to know whether or not grass pelleting will piece of work for them. Early experiences have shown that pelleting is not an "automated" process, and there are many tricks to making the procedure work well. Also, the economic science of the operation are not ever articulate.
Effigy one. Local renewable energy from grass pellets on the farm: ane)Switchgrass grows in field; 2) Bale storage; iii) Pellets manufactured in barn; iv) Home heated with pellet; 5) Carbon dioxide reabsorbed past growing crop
Pellet Use Today
Most pellets in utilize today are made from woods. They commencement became popular as a response to the fuel crises in the 1970s and early '80s every bit an industrial and residential fuel (Lisle 2013). The forest pellet market has recently seen some fluctuations due to the housing market crash in 2008, as well every bit the growth of the export market and variations in production capacity as new plants are built.
Wood pellets are an essential fuel for many Americans. The Pellet Fuels Institute approximates that there are 1,000,000 homes in the United states of america that rely on forest pellets for residential heating (Pellet Fuels Establish 2014). Wood pellets are burned in pellet stoves or boilers, providing hot air or hot water heat. Pellets in the The states are most exclusively used for home heating, although some commercial and institutional facilities have recently switched to pellet heat. Overseas, a big market for pellets exists, particularly in Europe where they are being used to co-fire with coal in power plants. However, worldwide use of pellets is almost exclusively of wood pellets, with very little grass pellet production to appointment. Still, boilers and stoves that are designed to use grass pellets equally fuel are available on the market.
Switchgrass for Pellets
Switchgrass (Panicum virgatum) is probably the top candidate for making grass pellets in the Northeast U.s.a.. Originally native to the prairies and grassy areas of the eastern Usa, the warm-season grass can be grown throughout virtually of the country. The crop has been planted for low-grade forage in some places, but information technology is more usually used for soil and wild animals conservation efforts because of its power to control erosion, add soil organic matter, ameliorate rainfall infiltration, and provide habitat for wild animals. In the Northeast, nigh 300,000 acres are enrolled in the USDA Conservation Reserve Program, with much of that being planted in switchgrass every bit an ecological measure (USDA Farm Service Agency 2014). Some farmers even abound switchgrass to improve habitat for hunting.
Figure 2. Switchgrass pellets
Switchgrass easily adapts to and yields well in marginal lands; therefore, information technology does not need to compete with food crops requiring fertile soils for establishment. Switchgrass tin have extremely deep root systems, which can go far suitable for many different soil types, including "droughty" soils that do non remain moist enough at the surface to back up typical crops. Switchgrass as well has very small nutrient requirements. Because of these characteristics, switchgrass more often than not does not take to displace principal crops that demand more fertile soils. The ingather tin grow up to 6 anxiety (ane.8 meters) alpine and yield four to vi dry tons per acre (nine to 13 tonnes per hectare) annually, although typical yields are often lower (Jacobson 2013). Switchgrass besides has relatively low costs associated with institution and maintenance, making information technology economically feasible to abound.
Invasiveness/spreading is usually not a large event for switchgrass because of its tendency to institute itself slowly. One time information technology is established, it competes very well with weeds and other plants; however, it does not naturally spread easily because seedlings tend to be sensitive to weed force per unit area, and every bit a result, it does not readily "accept over" a field without assist.
There are many different cultivars of switchgrass, which are divided into upland and lowland species. Upland species of switchgrass are naturally more accustomed to drier and colder weather condition found in the northern parts of the land, while lowland species originate in floodplain regions in the S (Jacobson 2013). Both types of species can flourish in the Northeast United states of america depending on the specific site. When buying switchgrass seeds, it is best to check with the local seed provider to detect cultivars that volition work well with your property. Some of the common types of switchgrass include 'Blackwell', 'Cave-In-Rock', 'Timber', and 'Kanlow' (Ernst Conservation Seeds 2014).
Figure 3. Switchgrass in the field
Pellets or Briquettes?
If yous densify grass into cylindrical pieces less than about twenty millimeters (¾ inch) in bore, it is typically called a "pellet." If information technology is larger, it is typically chosen a "briquette." While people are usually more familiar with pellets, briquettes may accept potential besides. Briquettes are ordinarily less expensive to manufacture, but they require heavier duty treatment equipment (augers, etc.). Because of this, briquettes are probably best suited for larger scale commercial and industrial uses.
"I love the way it heats my home. If I am looking for quick heat, I throw a few shovels of switchgrass pellets into my boiler." Will Brandau
Wood Crest Farm
This instance study takes a look at a subcontract that grows switchgrass and manufactures pellets on the farm for sale to the local community. The farm evaluated for the case study is Wood Crest Farm in Wapwallopen, Pennsylvania, which lies on the banks of the Susquehanna River in northeastern Pennsylvania (see Figure five). Wood Crest farm is located on stony silty loam soils, 93 per centum of those soils belonging to hydrological soil group C. The farm soils consist of Atherton, Braceville, and Chenango soils. Owned and operated by Will Brandau, the farm dates back to the mid-1800s when Volition'due south ancestors established the farm as a dairy performance with some hay fields toward the river. Will Brandau planted seven fields, for a full of twoscore acres, with switchgrass in 2006 with the dream of growing and processing his own fuel source, which he could then sell to people and businesses in his community. Switchgrass farming was a manner for Will to spend his days equally a retired teacher making fuel for his business firm and his community while likewise earning a supplemental income. Will has feel with not only growing switchgrass but too processing information technology into a usable form. He has worked with briquetters also every bit pelletizers, and runs his ain pelletizer in the lower level of the barn. His expertise and experience with switchgrass growing and pelletizing make this farm a great case of farm-based grass pellet production.
Figure 4. Volition Brandau, owner of Wood Crest Subcontract
Effigy five. Woods Crest Farm aeriform map showing switchgrass fields and barn. From Google, 2014.
The sections that follow requite details of the functioning at Wood Crest Farm, including equipment use, estimated costs, and miscellaneous tips on successful operation that the farmer has learned over the course of establishing the ingather and manufacturing pellets on the farm.
Applying this Example Study to Your Farm
This case report is intended to provide practical guidance to farmers interested in growing switchgrass and producing pellets on the farm. Keep in mind, even so, that every farm is dissimilar, and costs and labor can vary considerably from farm to farm. Not merely that, but productivity of fields and pelleting equipment can also vary a smashing deal. Lastly, a farmer'due south feel and skill can have a big impact on costs and performance. However, the data in this written report does provide some applied, experience-based information that should be very useful for farmers planning to try pellet production equally a business venture.
The following sections of the report are organized according to the principal phases of production: establishment, harvest, storage, and pellet product. In each section, a table lists operating costs for that step. Labor requirements are listed, just no price value is included (we assume that the labor is "free"). Equipment buy costs (toll of a tractor, mower, etc.) are treated every bit fixed startup costs and only listed in the "Costs Summary" section at the end of the report. State buy costs are naught (the farmer already owned the land) and yearly costs for land are assumed to equal the annual holding taxation charge per unit for the land. Equipment lubrication costs are assumed to equal 15 pct of fuel costs, and equipment maintenance costs are calculated based on guidelines from the American Society of Agricultural and Biological Engineers (2011).
Growing and Establishment
Switchgrass is an attractive energy crop because of its high yields and like shooting fish in a barrel maintenance. The crop's productivity throughout its multiple growing seasons relies on the successful establishment of this perennial warm-flavour grass. Described beneath are the strategies used at Woods Crest Farms to ensure the successful establishment of switchgrass.
Seed Diverseness
Wood Crest Farms uses a combination of grasses to promote biodiversity, wildlife habitat, and crop health. In addition to switchgrass, Will uses a mixture of big bluestem, Indian grass, and wildflower seeds. It is also a skilful idea to add together legumes into the seed mixture to provide nutrients and increase productivity. Other common species to incorporate are littoral panic grass, cordgrass, showy tick trefoil, wild sienna, and partridge pea (Ernst Conservation Seeds 2014). At Wood Crest Farm, some of the fields remained a mix of species after planting and establishment, whereas others tended to get dominated by switchgrass after a few years.
Site Selection and Preparation
Switchgrass can grow on a wide multifariousness of soil types, including marginal lands, only unlike varieties may be amend adjusted to different conditions, depending on the local climate, soil fertility, and soil moisture characteristics. Speak to your seed supplier earlier settling on a variety for your farm. More often than not, it makes more sense to grow switchgrass on marginal footing instead of good land--returns from food crops on good country are unremarkably much higher.
The most of import step in site preparation is the emptying of competing grasses and weeds. Weed competition is the main enemy of healthy establishment in switchgrass. Therefore, it is important to minimize the presence of inhibiting plants. At Wood Crest Subcontract, Will applies glyphosate and 2,four-D herbicide in the autumn flavor before planting then again two weeks earlier planting in the spring. Will begins planting in the early on spring, ordinarily in April, once the risk of frost has passed. Immediately before planting, Volition used a disk to selectively smooth out the soil in the few spots that had ruts. He did disc 1 of his smaller fields entirely--this was probably not necessary, and it seemed that the weeds were much more than vigorous in that field, probably considering the disking allowed more weed seeds to contact the soil and germinate.
| Item | Unit | Number Per Acre | Unit Cost | Acres | Cost Per Acre | Total Cost for forty Acres |
|---|---|---|---|---|---|---|
| Spraying in the Fall | ||||||
| Tractor operation | hours | 0.375 | $0.75 | 40 | $0.28 | $11.25 |
| Sprayer operation | hours | 0.375 | $0.21 | 40 | $0.08 | $3.15 |
| Herbicide | per acre | 1.000 | $thirty.00 | 40 | $30.00 | $i,200.00 |
| Fuel | gallons | 0.375 | $iii.75 | 40 | $ane.41 | $56.25 |
| Lube (fifteen% of fuel cost) | n/a | n/a | n/a | 40 | $0.21 | $8.44 |
| Labor | hours | 0.375 | $0.00 | 40 | $0.00 | $0.00 |
| Full: | $31.98 | $i,279.09 | ||||
| Spraying in the Spring | ||||||
| Tractor operation | hours | 0.375 | $0.75 | 40 | $0.28 | $11.25 |
| Sprayer operation | hours | 0.375 | $0.21 | 40 | $0.08 | $3.15 |
| Herbicide | per acre | 1.000 | $30.00 | 40 | $30.00 | $1,200.00 |
| Fuel | gallons | 0.375 | $iii.75 | 40 | $1.41 | $56.25 |
| Lube (15% of fuel cost) | n/a | n/a | northward/a | 40 | $0.21 | $8.44 |
| Labor | hours | 0.375 | $0.00 | forty | $0.00 | $0.00 |
| Full: | $31.98 | $1,279.09 | ||||
| Selective Disking (approx. 3 acres) | ||||||
| Tractor operation | hours | 0.50 | $vii.34 | 3 | $3.67 | $11.01 |
| Disk operation | hours | 0.50 | $0.95 | 3 | $0.48 | $1.43 |
| Fuel | gallons | 0.93 | $3.75 | 3 | $three.49 | $ten.46 |
| Lube (15% of fuel toll) | northward/a | northward/a | northward/a | 3 | $0.52 | $ane.57 |
| Labor | hours | 0.50 | $0.00 | 3 | $0.00 | $0.00 |
| Total: | $8.16 | $24.47 | ||||
Notes: Fuel use for herbicide spray is based on farmer measurements. Fuel use for other operations is based on typical fuel use rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each operation is listed in the Appendix. Lube cost is assumed to equal 15 percent of fuel cost per Edwards (2009). Maintenance costs based on the American Gild of Agricultural and Biological Engineers (2011) and reported in Edwards (2009). The cost of purchasing land and/or equipment is not included in this table; however, those costs are discussed in the "Price Summary" section of this report.
What Counts as Marginal State?
Switchgrass is often touted equally being a peachy crop for use on "marginal land." Then, what counts as marginal land? It turns out that many things could make a field "marginal," but it generally comes downwardly to whether or non the land is suitable for production of traditional food or feed crops. It could be that the soil has low fertility. Information technology could be that the land is wet, droughty, steep, or highly erodible. However, it could as well exist that the owner's situation makes the fields unsuitable for food production. In the case of Woods Crest Farm, the fields are in almost respects quite expert, only the farmer, existence semi-retired, was not in a position to put intensive attempt into the operation. That is what made this farm unsuitable for food or feed product, but suitable for switchgrass.
Planting
One of the fields (13.five acres) was thick with corn stubble, then Will had to mow information technology down earlier the no-till drill would work well in that field. Will as well obtained a permit and burned 2 of the fields (10 acres) prior to planting. A no-till drill was then used to apply seed to the fields. Information technology seemed that once the planter was running well, the biggest time waste material was when the motorcar had to be turned effectually to kickoff a new row. From a planting bespeak-of-view, fields that are long and narrow would probably be the most efficient.
Will uses a mixture of native grasses and wildflowers, non just switchgrass, to provide biodiversity in the field. The no-till drill is calibrated to the specific application charge per unit of each species, which is listed in the table below. The seeds are planted in rows ¼ inch deep and with vii inches between rows.
| Seed | Application Rate (Pounds Per Acre) |
|---|---|
| Switchgrass | 7 |
| Large Blue Stem | ane |
| Indian Grass | one |
| Native Wildflowers | 1/four |
Twenty-five acres of the fields were treated with a cultipacker afterwards seeding. (A cultipacker is a ridged or textured roller that is pulled behind a tractor, pressing downwardly the top layer of soil and improving seed-to-soil contact. Cultipackers are normally not needed for fields planted with a no-till drill, but if the drill is not planting seeds at a uniform depth, the cultipacker could feasibly help.) Will's impression is that the cultipacked fields had ameliorate formation rates than the noncultipacked fields, simply this was not carefully measured. Volition was also impressed with how vigorously the switchgrass started in the fields that were burned prior to planting. All the same, those fields probably have the about fertile soils on the farm, so the skilful growth may exist due to more than than the initial burndown of the fields. Costs for planting include the cost of equipment maintenance, seed, labor, and fuel. In this case, the planter was provided costless of charge past Pheasants Forever, a local conservation organization. Every bit a outcome, Will's maintenance price for that equipment was cipher.
| Particular | Unit of measurement | Number Per Acre | Unit Price | Acres | Price Per Acre | Total Cost for All Acres |
|---|---|---|---|---|---|---|
| Mowing of I Field (thirteen.5 acres) | ||||||
| Tractor functioning | hours | 0.l | $2.06 | thirteen.5 | $ane.03 | $thirteen.91 |
| Mower operation | hours | 0.fifty | $2.48 | xiii.5 | $1.24 | $sixteen.74 |
| Fuel | gallons | 0.66 | $3.75 | 13.5 | $2.48 | $33.41 |
| Lube (xv% of fuel price) | n/a | n/a | north/a | xiii.5 | $0.37 | $five.01 |
| Labor | hours | 0.50 | $0.00 | 13.5 | $0.00 | $0.00 |
| Total: | $5.12 | $69.07 | ||||
| Called-for of Two Fields (10 acres) | ||||||
| Labor | hours | 0.40 | $0.00 | ten | $0.00 | $0.00 |
| Full: | $0.00 | $0.00 | ||||
| Planting | ||||||
| Tractor operation | hours | 0.30 | $two.06 | 40 | $0.62 | $24.72 |
| No-till Drill performance | hours | 0.14 | $0.00 | xl | $0.00 | $0.00 |
| Switchgrass seed | pounds | 7.00 | $6.00 | twoscore | $42.00 | $i,680.00 |
| Bluestem seed | pounds | i.00 | $1.00 | 40 | $1.00 | $40.00 |
| Indian Grass seed | pounds | 1.00 | $1.00 | forty | $i.00 | $xl.00 |
| Wildflower seed | pounds | 0.25 | $25.00 | 40 | $half-dozen.25 | $250.00 |
| Fuel | gallons | 0.43 | $iii.75 | 40 | $i.61 | $64.50 |
| Lube (15% of fuel cost) | north/a | north/a | north/a | 40 | $0.24 | $9.68 |
| Labor | hours | 0.50 | $0.00 | 40 | $0.00 | $0.00 |
| Total: | $52.72 | $2,108.90 | ||||
| Cultipacking (25 acres) | ||||||
| Tractor performance | hours | 0.30 | $2.06 | 25 | $0.62 | $xv.45 |
| Cultipacker functioning | hours | 0.30 | $0.eighteen | 25 | $0.05 | $1.35 |
| Fuel | gallons | 0.43 | $3.75 | 25 | $one.61 | $forty.31 |
| Lube (15% of fuel cost) | north/a | n/a | n/a | 25 | $0.24 | $vi.05 |
| Labor | hours | 0.30 | $0.00 | 25 | $0.00 | $0.00 |
| Full: | $ii.53 | $63.sixteen | ||||
Notes: Operating time is based on farmer measurements. Fuel employ is based on typical fuel apply rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each operation is listed in the appendix. Lube cost is assumed to equal 15 percent of fuel cost per Edwards (2009). Maintenance costs are based on the American Lodge of Agricultural and Biological Engineers (2011) and reported in Edwards (2009). The cost of state use and/or equipment purchase is non included in this table; however, those costs are discussed in the "Cost Summary" section of this written report.
Establishment
Switchgrass takes at least two years to institute, and activity during this fourth dimension consists primarily of mowing for weed control. During this period, the switchgrass ingather is spending most of its effort developing its deep and circuitous root construction, which can be 6 to 8 feet deep. Every bit a effect, in that location may not be a lot of visible growth above the surface. Switchgrass seeds are relatively small and known to germinate slowly. This leads to a slow and long establishment (Foster et al. 2013). In fact, farmers who are growing switchgrass for the first time often think that they have a failed crop at the end of the first year since so piddling growth is visible.
Figure 6: Switchgrass at the end of the starting time twelvemonth.
Switchgrass'due south wearisome initial growth makes weed interference a large inhibitor of switchgrass institution. It is crucial to reduce weed competition during this growth phase. If the plant cannot establish its root organization early on, it will yield less biomass in the early years of harvest. At Wood Crest Farm, the fields are mowed three times during the summertime of the first yr (June, July, and August) with a rotary blade mower to reduce the amount of weed interference. Each fourth dimension, Will is careful to set the summit of the mower only above the superlative of the growing switchgrass. The mowing reduces contest for nutrients and moisture, and allows the switchgrass to receive more than light during the solar day. Volition strongly encourages farmers to use mowing as a weed control tool during the establishment of the ingather. Normally past the 2d year the switchgrass is able to oversupply out virtually weeds, but mowing during the first year makes a big departure.
| Detail | Unit | Number Per Acre | Unit Cost | Acres | Toll Per Acre | Total Cost for All Acres |
|---|---|---|---|---|---|---|
| Mowing (3 x xl acres) | ||||||
| Tractor operation | hours | 0.50 | $2.06 | twoscore | $three.09 | $123.threescore |
| Mower operation | hours | 0.50 | $2.48 | 40 | $3.72 | $148.80 |
| Fuel | gallons | 0.66 | $3.75 | 40 | $7.43 | $297.00 |
| Lube (15% of fuel cost) | n/a | due north/a | due north/a | 40 | $1.11 | $44.55 |
| Labor | hours | 0.50 | $0.00 | 40 | $0.00 | $0.00 |
| Total: | $xv.35 | $613.95 | ||||
| Selective Spraying (18.5 acres) | ||||||
| Tractor functioning | hours | 0.375 | $0.75 | 18.5 | $0.28 | $five.twenty |
| Sprayer operation | hours | 0.375 | $0.21 | xviii.5 | $0.08 | $1.46 |
| Herbicide | per acre | 1.000 | $30.00 | eighteen.5 | $30.00 | $555.00 |
| Fuel | gallons | 0.375 | $three.75 | eighteen.v | $1.41 | $26.02 |
| Lube (xv% of fuel cost) | n/a | due north/a | n/a | xviii.five | $0.21 | $3.90 |
| Labor | hours | 0.375 | $0.00 | 18.5 | $0.00 | $0.00 |
| Total: | $31.98 | $591.58 | ||||
| Land Cost, Year 1 | ||||||
| Taxes | per acre | ane | $25.00 | forty | $25.00 | $1,000.00 |
| Total: | $25.00 | $i,000.00 | ||||
Notes: Operating time is based on farmer measurements. Fuel apply is based on typical fuel use rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each operation is listed in the appendix. Lube toll is causeless to equal 15 percent of fuel cost per Edwards (2009). Maintenance costs are based on the American Social club of Agronomical and Biological Engineers (2011) and reported in Edwards (2009). The toll of state utilize and/or equipment purchase is not included in this table; all the same, those costs are discussed in the "Cost Summary" section of this study.
Harvesting
The switchgrass is non harvested until its second year because information technology is developing its root zone during that first year, so there will non be enough growth to effect in a reasonable harvest. At Wood Crest Subcontract, Volition gets a reduced yield (only about 1-third of the normal yield) in the second year and full harvests in following years. Harvesting at Wood Crest Subcontract is always washed in the spring earlier new growth begins. This allows the switchgrass to transport nutrients from the leaves back down to the root zone while it is standing in the fields over winter. This process allows Wood Crest Farm to not apply fertilizers to the fields.
Mowing
The switchgrass is harvested with a flail chopper at Wood Crest Farms. At that place are a few reasons for this. First, it chops the switchgrass into 12- to xiv-inch pieces every bit opposed to the total six- to eight-foot length of the grass. This allows for easy bailing. 2nd, the flail chopper tends to "depict upwards" stems that were pushed over by snow in the winter rather than leaving them on the basis unmowed. Tertiary, the flail chopper tends to cut some very small-scale pieces of leaf and stem that don't become picked up by the baler, thus leaving some biomass backside on the field to be composted for next twelvemonth'south crop. The final reason is that the flail chopper is adjusted to leave 6 to viii inches of the switchgrass on the plant instead of cutting information technology very close to the surface. This protects the switchgrass establish from damage and helps ensure that the switchgrass stub volition bend over during mowing to reduce the chance of tire puncture. Other types of mower (eastward.chiliad., sickle bar, disc, rotary) accept been used past other farmers and may be suitable depending on your particular situation.
Figure vii. Mowing the crop.
Regardless of your mower type, be on guard against sparks or heat that could first a fire in the field. Switchgrass fields are dense, and when they are harvested dry out, they are definitely flammable. The other prophylactic event to go along in mind is that dry switchgrass tin boot up quite a flake of grit when harvested--using a grit mask or enclosed cabin could be a very good idea.
Raking and Baling
One time the switchgrass is cut, it is and so raked into windrows for baling. Will uses both a round baler and a square baler. Information technology was noted that the switchgrass has the trend to clog the belts in the round baler. Considering of this, you need to plan to stop periodically to clean the belts during harvesting to prevent clogging. The round bales are good for storing large quantities of the grass. Yet, small square bales are easier to manage. The square bales are also preferred by some of Will's customers who purchase bales for employ as mulch or bedding.
On April 17-18, 2014, measurements were fabricated of the harvesting operations at Forest Crest Subcontract, including the time and labor required to rake and bale the ingather. The results of this functioning, displayed in Table 6, are normalized to prove the amount of time Will spends per acre.
Figure viii. Clearing crust from the round baler.
Effigy 9. A freshly made circular bale.
Fall or Leap Harvest?
Some farmers harvest their switchgrass in spring, while others harvest in the fall. Which is best? Fall harvest allows a more complete harvest (higher yield) and eliminates the problem of heavy snows pushing down ("lodging") the ingather. Jump harvest, however, normally results in the driest crop and gives extra time for nutrients to be leached out of the ingather, dorsum into the root zone. Some farmers try a combination approach-mowing in the autumn, then leaving the biomass over wintertime to exist baled in the spring. It's hard to say which approach is best, and it might depend on available markets, the specifics of your subcontract, and how you lot choose to manage it.
Yield
Some researchers have reported switchgrass yields of up to and over 5 dry tons per acre. This may be possible in some locations, just experience at Woods Crest Farm has been that the actual yield from switchgrass is much lower--more than similar 3 dry tons per acre, with some fields producing more and some producing less. Iii dry tons per acre corresponds to most xi big round bales or 160 minor square bales per acre.
| Item | Unit | Number Per Acre | Unit of measurement Price | Acres | Cost Per Acre | Full Cost for All Acres |
|---|---|---|---|---|---|---|
| Mowing | ||||||
| Tractor functioning | hours | 0.50 | $2.06 | 40 | $one.03 | $41.20 |
| Mower operation | hours | 0.50 | $2.48 | 40 | $1.24 | $49.60 |
| Fuel | gallons | 0.66 | $3.75 | 40 | $2.48 | $99.00 |
| Lube (fifteen% of fuel cost) | n/a | n/a | n/a | 40 | $0.37 | $14.85 |
| Labor | hours | 0.50 | $0.00 | 40 | $0.00 | $0.00 |
| Total: | $five.12 | $204.65 | ||||
| Raking | ||||||
| Tractor operation | hours | 0.twenty | $0.75 | 40 | $0.xv | $6.00 |
| Rake performance | hours | 0.20 | $0.09 | twoscore | $0.02 | $0.72 |
| Fuel | gallons | 0.24 | $3.75 | 40 | $0.90 | $36.00 |
| Lube (fifteen% of fuel price) | n/a | n/a | due north/a | 40 | $0.14 | $5.40 |
| Labor | hours | 0.20 | $0.00 | forty | $0.00 | $0.00 |
| Total: | $1.20 | $48.12 | ||||
| Baling | ||||||
| Tractor operation | hours | 0.55 | $four.04 | forty | $two.22 | $88.88 |
| Baler operation | hours | 0.55 | $seven.70 | 40 | $4.24 | $169.40 |
| Fuel | gallons | 0.80 | $3.75 | 40 | $three.00 | $120.00 |
| Lube (15% of fuel cost) | n/a | n/a | northward/a | 40 | $0.45 | $18.00 |
| Labor | hours | 0.55 | $0.00 | twoscore | $0.00 | $0.00 |
| Total: | $9.91 | $396.28 | ||||
| Land Cost | ||||||
| Taxes | per acre | one.00 | $25.00 | 40 | $25.00 | $one,000.00 |
| Total: | $25.00 | $1,000.00 | ||||
Notes: Operating fourth dimension is based on farmer measurements. Fuel use is based on typical fuel use rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each functioning is listed in the appendix. Lube cost is assumed to equal 15 per centum of fuel cost per Edwards (2009). Maintenance costs are based on the American Social club of Agronomical and Biological Engineers (2011) and reported in Edwards (2009). The cost of land employ and/or equipment purchase is not included in this table; however, those costs are discussed in the "Cost Summary" section of this report. Land taxation is based on farmer experience and a survey of like properties in the expanse.
| Time to Mow (Minutes/Acre) | Time to Rake (Minutes/Acre) | Fourth dimension to Bale (Minutes/Acre)1 | Comments | |
|---|---|---|---|---|
| Measured Values | 46 | 17 | 54 | Field shows lodging. Stems lying on the basis from previous winter. |
| Textbook Values2 | 10 | 8 | 14 | These numbers are pretty quick and probably but apply to very large fields, highly experienced operators, and equipment that is in perfect status. |
| Values Used for This Case Study | 30 | 12 | 33 | These numbers are a compromise between the very irksome going measured in 2014 and the book values. They represent a reasonable gauge of how chop-chop operations usually proceed at the farm. |
Notes: (1) The bale concatenation broke during functioning, so the baling procedure was finished for the day after. In 16 minutes two round bales were fabricated weighing 560 and 630 pounds each; (2) Information for mower conditioner, rake, and rectangular baler, and 12-foot swath from the American Society of Agricultural and Biological Engineers (2011).
Storage
After harvest, the baled grass is stored until ready for pellet production. Will uses a tractor with a bale spear to movement the bales to a storage area almost the barn. 1 purpose for this is that the optimal wet content for switchgrass pellets is betwixt 12 and fifteen percent and the bales come off the fields at a moisture content of 6 to 8 percent. As they sit in the open up air, the bales tend to absorb a chip of moisture, bringing them closer to the optimum level for pellet production. Volition stores most of the switchgrass outside. According to Will, indoor storage does not bear upon the moisture content every bit much as outdoor storage. Will has stored bales on the ground under the open up air, but he now prefers to utilise one-time pallets or steel siding to keep the bales off the ground, and he obtained some reclaimed rubber roofing to utilise as tarps to keep the bales from getting too wet. The rubber roofing is heavy enough that it doesn't accept to be tied downward in the wind.
When the bales are stored outside there is some loss to spoilage, but Will reports that it is minimal. The outmost layer of the round bail gets moisture and soggy, simply the interior remains in adept condition. Will has found that, even later a few years, round bales that are stored exterior still pelletize well with limited losses from rotting. Limited indoor storage space is ane reason Will stores the bales of switchgrass outside; it is much more than cost effective to shop the switchgrass outdoors. Nosotros have assumed a ten percent mass loss in this study.
Figure 10. Former unused bales (top) and newer tarped bales in storage (bottom).
| Item | Unit of measurement | Number Per Acre | Unit of measurement Cost | Acres | Cost Per Acre | Total Cost for All Acres |
|---|---|---|---|---|---|---|
| Handling/Storage | ||||||
| Tractor operation | hours | 0.25 | $two.06 | 40 | $0.52 | $20.lx |
| Fuel | gallons | 0.66 | $3.75 | forty | $2.48 | $99.00 |
| Lube (xv% of fuel cost) | n/a | n/a | due north/a | forty | $0.37 | $fourteen.85 |
| Labor | hours | 0.25 | $0.00 | 40 | $0.00 | $0.00 |
| Total: | $3.36 | $134.45 | ||||
Notes: Operating time is based on farmer measurements. Fuel utilise is based on typical fuel use rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each operation is listed in the appendix. Lube cost is assumed to equal xv percentage of fuel cost per Edwards (2009). Maintenance costs are based on the American Lodge of Agricultural and Biological Engineers (2011) and reported in Edwards (2009). The price of country employ and/or equipment purchase is not included in this table; however, those costs are discussed in the "Cost Summary" section of this report.
"I dear to repurpose things. If I tin can find a way to reuse something in a different fashion, that excites me." Will Brandau
Pellet Product
In one case it is time to brainstorm producing pellets, Will first takes the switchgrass bales and grinds them in a bale buster, which rotates and chops the bales, producing a coarse-footing material. From at that place, the switchgrass goes into a ¼-inch-screen hammer mill. The switchgrass is then placed in super sacks for storage. Wood Crest Farm uses a 55-horsepower diesel fuel pellet mill to form the pellets. (Run into Appendix A for more information about the pellet mill.) Will suggests that a three-phase electric pellet press would exist more cost effective than his diesel pellet printing, simply three-stage power was not available at the farm. The auto at Woods Crest Farm has produced at almost 400 pounds (182 kg) of switchgrass pellets in one hour, although its rated capacity is one,500 pounds per hour.
At Wood Crest Subcontract, Will adds switchgrass material every bit presently as he turns the machine on. Pellets may not course immediately while the machine is warming upwards. Volition takes the unpelletized "fines" and re-adds them to the feeder until he starts getting pellets. The heat needed to form the pellets comes from the friction of the fabric running through the system, so it may take a trivial while before the automobile begins to produce pellets. It takes about 10 minutes for Volition'due south machine to start producing pellets. He can tell it is set when the motorcar starts to produce steam.
| Operation rating | Product rate (kG hr-1) |
|---|---|
| Poor | 16.viii |
| Typical | xc |
| All-time | 182 |
| Motorcar rating | 682 |
During June 2013, a team of students measured the pelleting procedure at Forest Crest Subcontract. Their findings were that the pelletizer produced just sixteen.8 kilograms of pellets per hr. That is quite tedious--simply 9 per centum of the height rate that Will has achieved in the past, and a mere ii.5 percent of the rated output of the machine. This wearisome production charge per unit was due to the fourth dimension needed to warm up the automobile and to suit the operating conditions until the pelletizer started working properly. This illustrates a vital point that farm pellet manufacturers need to understand: information technology is very difficult to get high output from pelletizers, and you will probably never come close to achieving the machine'due south rated output. Keep that in mind so that you are non sorely disappointed when yous find out how much time it takes to make pellets.
Effigy eleven. Equipment used for making pellets at Wood Crest Farm from height to lesser: (a) bale grinder and hammer factory, (b) basis switchgrass for pelleting, (c) pelletizer, (d) cooling rack.
How Exercise Pellets Grade?
Almost pelletizers work past using a steel roller to force ground biomass through holes in a thick metal dice. But why does this cause the basis material to turn into a pellet? Well, the ground biomass is compressed when this happens, and a slap-up deal of heat is also produced. If it gets hot enough (~80°C), the lignin in the biomass will start to become soft and tacky, and serves equally a natural "binder" to hold the ground particles together in its dumbo pellet shape. If all goes well, by the time the biomass is pushed out the far finish of the die, it will have formed a dense pellet. All naturally occurring wood and grasses incorporate lignin, just forest tends to have a higher fraction of lignin--about 22 to 24 percent by mass (switchgrass is typically 12 to 15 percent). Nevertheless, even though grasses are lower in lignin, experiments accept shown that they still form high-quality pellets without the utilize of actress binders.
Production Rate
One of the master reasons the production rate is so depression relative to the rated output has to do with the feedstock--switchgrass is known to be slow to pelletize. It could besides be that the rated output of the machines is somewhat overly optimistic. Regardless of the reason, the low production rate and the variable production charge per unit from solar day to mean solar day can exist a real challenge. Will has not tried to automate his system however, in large office due to the variability in pelletizer performance. He often needs to exist on hand to tweak the system to keep things running. Another of import betoken to stress is that it takes time and exercise to learn how to operate a pelletizer well. You will probably spend quite a while making mistakes before you lot finally start making pellets, and it will be a while after that earlier you lot get good at it. A hammer and dial is handy to take for those times when the die gets clogged.
Will suggests that having the correct moisture content yields the best results. If the switchgrass is too dry out, Will adds water to it until he reaches the desired moisture content. He hasn't carefully controlled moisture content yet, but the bales, which are well-nigh 4 to 7 percent moisture, are definitely too dry out. Most recommendations land that feedstock moisture content should exist in the 12 to 18 percent range. In addition to water, Will has tried adding lime, but that didn't seem to assist.
Having the rollers and the dice at the right tightness is another important element. This setting will vary from machine to automobile. After some experimentation, Will institute that if he puts 3 sheets of sparse cardboard (from a case of soda cans) between the dice and roller and so tightens the rollers down with a wrench, the resulting spacing is perfect for his automobile.
Some other thing that helps is to have some "soft" biomass on hand for when you lot are set up to shut down; add together a scoop of ground soybeans or dried distillers grains to the automobile and let it run through the die. That way, switchgrass won't be in the die to cool, harden, and form a very hard plug.
The pellets are very warm and soft once they come out of the press, then they are placed on screen racks to cool and harden. They are stored in super sacks and bagged as needed for shipping. Will receives the super sacks from a local pet store, which receives pet food in the super sacks and then gives them to Will to reuse instead of throwing them away. This saves Volition about $15 per bag.
| Item | Unit | Units per Ton of Feedstock | Unit Cost | Tons Per Yr | Total Toll Per Ton of Feedstock | Total Cost |
|---|---|---|---|---|---|---|
| Barn Use | n/a | n/a | $0.00 | 108 | $0.00 | $0.00 |
| Total: | $0.00 | $0.00 | ||||
| Grinding | ||||||
| Tractor PTO for Grinder | hours | 1.12 | $2.06 | 108 | $2.31 | $249.xviii |
| Fuel | gallons | 1.48 | $3.75 | 108 | $v.55 | $599.40 |
| Lube (15% of fuel cost) | n/a | n/a | n/a | 108 | $0.83 | $89.91 |
| Grinder operation | hours | 1.12 | $3.lx | 108 | $4.03 | $435.46 |
| Labor | hours | 1.12 | $0.00 | 108 | $0.00 | $0.00 |
| Total: | $12.72 | $ane,373.94 | ||||
| Hammer Milling | ||||||
| Hammer mill performance | hours | one.12 | $0.22 | 108 | $0.25 | $26.61 |
| Fuel | gallons | 0.59 | $3.75 | 108 | $ii.21 | $238.95 |
| Lube | north/a | n/a | n/a | 108 | $0.33 | $35.84 |
| Labor | hours | included in grinding chore | $0.00 | 108 | $0.00 | $0.00 |
| Total: | $2.79 | $301.40 | ||||
| Pellet Making | ||||||
| Pellet manufacturing plant operation | hours | x.0 | $0.05 | 108 | $0.51 | $55.08 |
| Die replacement | hours | 10.0 | $0.40 | 108 | $4.00 | $432.00 |
| Fuel | gallons | 12.i | $3.75 | 108 | $45.38 | $four,900.50 |
| Lube | n/a | n/a | north/a | 108 | $half dozen.81 | $735.08 |
| Labor | hours | 10.0 | $0.00 | 108 | $0.00 | $0.00 |
| Total: | $56.69 | $half dozen,122.66 | ||||
| Drying and Bagging | ||||||
| Sacks for pellets | number of super sacks | 5.0 | $0.00 | 108 | $0.00 | $0.00 |
| Labor | hours | 1.0 | $0.00 | 108 | $0.00 | $0.00 |
| Total: | $0.00 | $0.00 | ||||
Notes: Operating time is based on farmer measurements. Fuel apply is based on typical fuel use rates from Helsel and Oguntunde (1985) and published in Grisso et al. (2010). Equipment used for each operation is listed in the appendix. Lube toll is causeless to equal 15 percent of fuel cost per Edwards (2009). Maintenance costs are based on the American Society of Agricultural and Biological Engineers (2011) and reported in Edwards (2009). The cost of land employ and/or equipment purchase is not included in this table; however, those costs are discussed in the next section.
Cost Summary
The cost of a switchgrass operation will vary from farm to subcontract because some of the equipment may already be readily attainable without the demand for purchase. This section summarizes costs for Wood Crest Subcontract and provides a typical range of costs that other farmers might meet depending on their situation. The costs associated with switchgrass growth and pellet production are classified here as either a fixed cost or variable cost that depends on the size of performance. The grant and aid programs that Forest Crest Farms received volition as well exist considered in the total cost.
Stock-still Costs
Fixed costs are the amounts paid for equipment, material, etc. Information technology does not depend on farm size, inside reason. The tractors and field implements were generally purchased used, which helped keep costs down.
The barn and land are already owned, so at that place were no fixed costs for purchasing the subcontract or building the barn. If the subcontract were non already owned, the purchase cost of the state (or rental toll, if rented) would have to be factored in besides. In the region, state costs of $1,000 to $2,000 per acre for tillable land are not uncommon, and land rental rates every bit high as $150 per acre per year have been seen.
| Equipment | Brand | Cost at Wood Crest Farm |
|---|---|---|
| Tractors | ||
| Discing, Planting, Baling | International 1086 | $9,000 |
| Mowing | International Super C | $4,000 |
| Spraying, Raking | Ford 1300 | $half-dozen,500 |
| Bale Grinding | NorTrack Diesel | $iv,000 |
| Total: | $23,500 | |
| Field Implements | ||
| Sprayer | $625 | |
| No-Till Drill | loaned past Pheasants Forever | $0 |
| Flail Mower | AVCO/New Idea Cut/ditioner | $600 |
| Wheel Rake | Tonutti P4/94 on a Ford 1300 Tractor | $900 |
| Circular Baler | Gehlbale1500 | $one,500 |
| Square Baler | Sperry New Holland 273 | $900 |
| Full: | $4,525 | |
| Pelleting Equipment | ||
| Barn | Wood Postal service Frame Traditional Barn | n/a |
| Bale Grinder | Kidd Bale Chopper five-4 | $4,000 |
| Hammer Mill | $one,600 | |
| Pellet Manufactory | 55-hp Diesel fuel Unit | $5,200 |
| Augers and Conveyors | For automating pellet procedure | $ii,600 |
| Spare Parts | $700 | |
| Shipping | $2,000 | |
| Total: | $16,100 | |
Variable Costs
Here, variable costs are assumed to be the expenses that change depending on the size of the performance. Variable costs can exist function of the startup or part of regular operations. Go on in mind that fuel rates will change from region to region and besides labor prices will vary. The costs listed here are scaled "per acre" too as the total for the farm.
| Per Acre | Total | |
|---|---|---|
| Site Prep | $72.11 | $two,582.64 |
| Planting | $60.37 | $2,241.12 |
| Establishment | $72.33 | $2,205.53 |
| Full: | $204.80 | $7,029.29 |
| Per Acre | Full | |
|---|---|---|
| Harvest | $41.23 | $1,649.05 |
| Storage | $iii.36 | $134.45 |
| Pelleting | $194.95 | $7,798.00 |
| Full: | $239.54 | $9,581.50 |
| Item | Per Acre | Full |
|---|---|---|
| Fuel and Lube (Tractors, Mills) | $175.17 | $7,006.78 |
| Equipment Budget | $39.37 | $ane,574.72 |
| Labor | $0.00 | $0.00 |
| State Cost | $25.00 | $1,000.00 |
| Buildings, Packaging | $0.00 | $0.00 |
| Full: | $239.54 | $9,581.50 |
Grants and Assistance
Starting upwardly a new farm performance can exist very expensive, so Will tapped into some funding resources to help kickoff the toll of his operation. Specifically, Will received grant money through the REAP, EQIP, and WHIP grants. These grants were received at the first of the projection at Wood Crest Farms. Volition does non receive any type of yearly funding; these grants have aided in the startup funding, but agricultural output has had to be self-sustaining since.
The Rural Energy for America Program (REAP) is a fiscal help programme supported by the United States Department of Agriculture (USDA) to help agricultural producers and rural small businesses purchase, install, and construct renewable energy systems. This grant provided Will with 25 percent of the pelleting equipment cost. Co-ordinate to Volition, the procedure of filing for this programme was the lengthiest of all the programs with the concluding application consisting of 25 pages. Later on Will'southward application was processed, a member of the Conservation Committee came out to do a field inspection.
The 2d grant Will received for Woods Crest Farms was the Environmental Quality Incentives Program (EQIP) grant, which is a conservation grant promoted through the USDA's Natural Resources Conservation Service (NRCS). EQIP provides financial and technical assistance to farmers and other landowners to help them improve wildlife habitat, air quality, and water quality. This program provided the funds to allow Will to plant 25 acres of grass. In order to receive this funding, Will had to create a conservation plan, also known as the EQIP programme of operations. With the aid of a biologist from the NRCS, they were able to put this document together.
The final grant Will utilized for his operations was the Wildlife Habitat Incentive Program (WHIP). This grant provided funding for Will to found 15 acres of grass. Notwithstanding, this program was merged with the EQIP grant afterward the latest Subcontract Beak. Funding for this blazon of conservation endeavour can be received through the EQIP program.
In decision to this section, Will recommends that farmers consider the timeline from application to collection of funds. In the case of Wood Crest Farms, it took a long time for Will to hear back near his applications. The granting agencies took every bit much equally two to three years to articulate the system and send the funds to Will.
| Grant Source | Amount Per Acre | Number of Acres | Total |
|---|---|---|---|
| EQIP, Year 1 | $350 | 25 | $8,750 |
| EQIP, Year 2 | $180 | 25 | $4,500 |
| EQIP, Year 3 | $180 | 25 | $4,500 |
| WHIP | $380 | 15 | $5,700 |
| REAP | due north/a | n/a | $iv,000 |
| Total: | $27,450 |
Total Costs
The full toll of the pelleting functioning (broken downward according to fixed costs) and operating costs for each of the major steps in the process is shown beneath.
| Amount Per Acre | Total Toll | |
|---|---|---|
| Startup Costs | ||
| Fixed: Equipment | $863.13 | $44,125.00 |
| Variable: Site Prep | $72.11 | $ii,582.64 |
| Variable: Planting | $60.37 | $2,241.12 |
| Variable: Establishment | $72.33 | $2,205.53 |
| Grant Support | -$686.25 | -$27,450.00 |
| Net Total | $23,704.29 | |
| Ongoing Costs (per twelvemonth) | ||
| Variable Costs | ||
| Harvest | $41.23 | $one,649.05 |
| Storage | $three.36 | $134.45 |
| Pelleting | $194.95 | $seven,798.00 |
| Total | $239.54 | $9,581.50 |
Price per Ton
If we consider that the yield is three tons per acre, with ten per centum storage loss, and a final moisture content in the pellet similar to that of the original feedstock, we finish upwardly with a total production of 2.7 tons of pellets per acre, which corresponds to $88.72 per ton. (Remember that this cost does not include any labor, does not account for paying back equipment or state costs, has nil profit margin, and assumes that 100 percent of pellets are sold.) Most of the cost (well-nigh eighty percentage) is due to the pelleting operation itself, with the remainder due to field operations. If you pause down the costs according to the type of expense, you find that most of Will'south expenses (over 70 percent) are for fuel and lube costs.
This adding assumes no labor costs, no cost for using the barn, and land costs merely equal to the annual revenue enhancement rate for the land. Will is fortunate to have those resources available for his functioning. If not, the costs would be much college. For example, a labor cost of $ten per hr would increase product costs to $215 per ton. A land cost of $150 per acre (just no labor costs) would increment product costs to $135 per ton. Combining the $10 per hour for labor and the $150 per acre for land would result in a product price of $261 per ton. As you can see, the availability of depression-cost country, labor, and other facilities tin can make a huge departure to the lesser line.
This calculation also assumes that all of the switchgrass is harvested and pelletized. If all of the switchgrass is harvested but only one-half is pelletized, the product toll rises to $105 per ton of pellets. Since the marketplace for grass pellets is still somewhat limited, it makes sense to call up about potential markets for the baled and ground fabric as well as the pellets.
Figure 12. Cost savings from switching to grass pellets.
Markets for Switchgrass, Pelletized or Not
"Switchgrass tin can be a substitute for nigh any application of baled hay." Will Brandau
The intended stop market for switchgrass is in pellets or briquettes to exist used equally residential or industrial heating fuel. Pellet stoves tin can provide very efficient heating that is much less expensive for the owner than a petroleum-based product. People's bodily cost savings when switching to pellets will vary depending on the fuel they are currently using and the price they are paying, but in nigh cases, the savings is significant. Effigy 12 shows how much savings people can expect when switching from fuel oil or propane to grass pellets. Fuel oil and propane are two common heating fuels in the Northeast United States, specially in rural areas.
The manufacture is relatively new, and so information technology will take fourth dimension to convince people that grass pellets are a good replacement for wood and petroleum. So far, Will has been his own best customer for habitation heating with grass pellets. Since he is able to make much more than than he needs for himself, Will has looked to other market opportunities in order to maximize sales and profits from his switchgrass product operation. This includes both free energy and nonenergy uses of the material.
Mulch Markets
Will sells the baled or shredded switchgrass to local businesses and farms. Basis switchgrass is a peachy product for mulching lawns and equally a wood mulch substitute in gardens. Will sells the switchgrass to a local landscaper and a hardware and garden store. Co-ordinate to his customers, they savour the switchgrass because it'southward cheaper than the products they were previously using on lawns and gardens and works just besides if not improve. Will likewise mentioned that the square bales of switchgrass sell improve than the round bales for landscaping applications considering it is easier to handle in that grade. People are often unsure virtually using switchgrass for mulch, simply once they have tried it and come across how it performs, they tend to get great enthusiasts and promote it to others.
Effigy thirteen. Switchgrass--baled, ground, or pelletized--makes an excellent mulch.
Fauna Bedding
Another market for ground switchgrass is fauna bedding. Will sells his product to a few beefiness cattle farms in the area. He also sells quite a big amount of the footing grass to chicken farmers to be used as coop bedding. Farmers have reported dorsum to Will that they need to change their bedding less ofttimes, and take better operation than with other bedding materials.
Absorbents
Other switchgrass growers have found that switchgrass pellets tin be made purposely loose and sold equally an absorbent. Switchgrass can be used on construction sites that require erosion control. It tin can also exist used for municipal purposes to direct rainfall runoff. It seems the needs of switchgrass volition vary by region and what markets flourish there. Creativity and persistence have immune Will to discover buyers for his production.
Large Customers
One of the upcoming ideas in switchgrass pelleting is switchgrass co-ops for large-scale fueling. If multiple growers and producers collaborate and combine their efforts, they could serve large clients such as schools, hospitals, industries, etc. Gain would exist divided amid all the farmers and they would have a steady customer base and a consistent revenue stream. Will has attempted this type of model, simply unfortunately, problems with briquetter performance prevented that effort from succeeding.
Conclusions
In conclusion, starting up a new switchgrass pellet functioning can exist a way to generate income using marginal lands to create sustainable biomass energy. Switchgrass will crave a bit of land, merely information technology simply needs to be planted one time, and then once the crop becomes established, it will continue to grow and require relatively fiddling maintenance. It can be harvested yearly and used in a variety of markets. The switchgrass can be pelletized using some specialized equipment to be used as a heating fuel or it can exist sold as a mulching material in baled or ground grade.
Switchgrass has the power to create an entirely new acquirement stream for a crop that requires a relatively small amount of input. There are many uses for the crop. For example, it tin exist grown every bit a buffer aslope traditional crops, such as soybeans or corn. There are many energy and nonenergy uses for switchgrass, but it'due south a affair of finding the local markets. Will Brandau has taken the risk of beginning a switchgrass farm in order to heat his own home with a renewable energy source, provide others with this clean source of free energy, and be a pioneer so others can learn from his experiences to grow and make switchgrass pellets themselves.
The toll of growing and making switchgrass pellets at Wood Crest Farm is about $89 per ton. Notwithstanding, this does not include any labor costs or count the significant startup costs that Will is paying off over fourth dimension. Other farmers may observe their costs to be college or lower depending on the specifics of their situation.
References
American Social club of Agricultural and Biological Engineers. 2011. Agricultural machinery Management Data. ASABE Standard ASAE D497.vii. St Joseph, MI: American Society for Agricultural and Biological Engineers, March 2011.
Anyang Gemco Energy Machinery Co. "Diesel Pellet Mill." (accessed March 2014).
Brandau, Due west. "Wood Crest Farm Pellet Production." Telephone interview, March 2014.
Buffington, D. 2013. Energy Selector. University Park: Penn Country Extension.
Edwards, Westward. 2009. Estimating Farm Machinery Costs. Iowa Land University Extension Publication PM-710. Ames: Iowa State University.
Ernst Conservation Seeds. "Switchgrass." (accessed April 2014).
Foster, G., K. Chengjun, and T. Butler. 2013. "Effects of Row Spacing, Seeding Rate, and Planting Date on Establishment of Switchgrass." Crop Sci 53, no. 1: 309 -xiv.
Google. 2014. Aeriform photo of Wapwallopen, Pa., area. www.google.com (accessed May 2014).
Grisso, R., J. Perumpral, D. Vaughan, G. Robertson, and R. Pitman. 2010. "Predicting Tractor Diesel Fuel Consumption." Virginia Cooperative Extension Publication 442-073. Blacksburg: Virginia Polytechnic Institute and State Academy.
Helsel, Z., and T. Oguntunde. 1985. "Fuel Requirements for Field Operations with Energy Saving Tips." In Farm Energy utilisation: Standards, Worksheets, Conservation, edited past C. Myers. E Lansing: Michigan State University.
Jacobson, Chiliad. Renewable and Alternative Free energy Fact Sheet: NEWBio Energy Ingather Contour--Switchgrass . University Park: Penn State Extension, 2013.(accessed October 2014).
Lisle, B. 2013. "The History of the Wood Pellet Industry on the Eastward Coast." In Forest-Based Energy in the Northern Forests, edited by M. Jacobson and D. Ciolkosz. New York: Springer Science and Concern Media.
Lu, N., and R. W. Rice. 2011."Characteristics of Woods Fuel Pellet Manufacturers and Markets in the Usa, 2010." Wood Products Journal 61, no. 4: 310-15.
Pellet Fuels Institute. 2011. "What Are Pellets?" (accessed March 2014).
Motorway, A. 2014. "Machinery Custom Rates." United States Section of Agriculture National Agricultural Statistics Service.
Spelter, H., and D. Toth. 2009. "North America'due south Wood Pellet Sector." USDA Forest Service (access March 2014).
USDA. "Biomass Crop Help Program." (accessed June 2014).
USDA Subcontract Service Agency. 2014. "Conservation Reserve Program Monthly Crop Acreage Written report." (accessed May 2014).
USDA Natural Resources Conservation Service. "Environmental Quality Incentives Program." (accessed April 2014).
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Wilson, T. 2014. Grass Energy in Vermont and the Northeast: State of the Science and Technology. Prepared by Wilson Technology for the Vermont Sustainable Jobs Fund.
Appendixes
Appendix A: Pellet Press Diagram
- diesel engine
- clutch
- infeed hopper
- rollers
- dice
- pellets exiting pelletizer
- gear box
The feedstock is loaded into the infeed hopper and forced through to the die, where the rut and pressure of the machine press the switchgrass into a cylindrical shape and the natural lignin of the switchgrass starts to cook. This acts every bit the gum that holds the pellets together.
Appendix B: Schedule of Operations at Wood Crest Farm
Table showing the schedule of operations at Wood Crest Farms for making switchgrass biomass pellets.
Appendix C: Equipment List for Wood Crest Farm
The post-obit list shows which pieces of major equipment are used for the different operations at the subcontract. Notation that some tractors are used for multiple tasks.
| Spraying Operations | |
|---|---|
| Tractor | Ford 1300, 160-hp Diesel 2WD |
| Sprayer | NorthStar 3-Pt. Broadcast and Spot Sprayer (55 Gallon) |
| Discing Operations | |
| Tractor | International 1086, 131-hp Diesel 2WD |
| Discer | (not recommended by farmer for use) |
| Planting Operations | |
| Tractor | International 1086, 131-hp Diesel 2WD |
| Planter | No-till drill |
| Mowing Operations | |
| Tractor | International super C 24-hp 2WD |
| Mower | New Idea/Avco Cut-ditioner |
| Raking Operations | |
| Tractor | Ford 1300, 160-hp Diesel 2WD |
| Rake | Tonutti P4/94 |
| Baling Operations | |
| Tractor | International 1086, 131-hp Diesel 2WD |
| Baler | Gehl Gehlbale 1500 |
| Bale Handling Operations | |
| Tractor | International Industrial 2410 w/bale spear |
| Pelleting Operations | |
| Tractor (to run bale grinder) | Nortrac 25XT 25-hp Diesel fuel 4WD |
| Bale Grinder | Kidd Bale Chopper iv-5 |
| Hammer Mill | 22-hp Diesel Hammer Mill |
| Pelletizer | 55-hp Diesel Pellet Mill |
Appendix D: Acknowledgments
This project was supported by the Northeast Sustainable Agronomics Research and Education (SARE) program. SARE is a programme of the National Institute of Food and Agriculture, U.S. Section of Agronomics. Significant efforts have been made to ensure the accuracy of the material in this report, merely errors do occasionally occur, and variations in system performance are to be expected from location to location and from yr to year.
Many thanks to the student inquiry assistants working on this project: James Crawford, Vincent Vendetti, and Nichole Heil.
Farm Owner:
Will Brandau
31 Smith Mtn. Road
Wapwallopen, PA 18660
Email: willbrandau@gmail.com
Case Study Project Director:
Dan Ciolkosz
Penn Country Extension
Department of Agricultural and Biological Engineering
249 Ag Applied science Building
Academy Park, PA 16802
E-mail: dec109@psu.edu
Written by Nichole Heil and Daniel Ciolkosz, Penn Land Extension. Photos by Daniel Ciolkosz. Reviewed by West. Brandau, S. Goldberg, M. Jacobson, G. Lee, and R. Miller.
Source: https://extension.psu.edu/on-farm-production-of-biomass-grass-pellets-a-case-study
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