Document ID: EPA-HQ-OW-2005-0037-0054
Agency: epa
Document Type: Supporting & Related Material
Title: 
Posted Date: 2006-06-30T04:00Z

Storage
Pond
Design
(
CAFO
Cost
Report
p.
5­
53­
65)

Steps
to
design
storage
ponds:

1)
Determine
necessary
pond
volume.

Pond
Volume
=
Sludge
Volume
+
Runoff
+
Net
Precipitation
+
Design
Storm
+
Freeboard
Design
Storm
25
year,
24
hour
event
Avg.
Precipitation
wettest
6
month
period
of
the
past
25
years
Pond
Volume
180
days
of
storage
Freeboard
1
foot
minimum
Sludge
Volume
(
cf)
=
Sludge
Accumulation
x
Runoff
Solids
Runoff
Solids
(
lb)=
total
runoff
volume
(
cf)
x
Density
of
Water
(
62.4
lb/
cf)
x
1.5%
(
solids)

Net
Precipitation
=
Avg.
6­
month
Precipitation
­
(
Annual
Evaporation/
2)

Runoff
(
cf)
=
0.4
x
Avg.
Precipitation
(
ft)
x
composting
area
(
sq.
ft)

Design
Storm
Runoff
(
cf)
=
(
Precipitation
(
ft)
­
0.042)
x
composting
area
(
sq.
ft)

2)
Calculate
dimensions
and
configuration
of
pond.

Pond
Volume
(
square
structure)
=
0.5
Height
x
(
Base
Area
+
Top
Area
+
(
Base
Area
x
Top
Area)^
0.5)

Cost
Model
will
calculate
the
dimensions
of
the
basin
that
yield
the
desired
volume.

Dimensions
needed
for
Cost
Calculations:

Base
Length
Base
Width
Top
Length
Top
Width
Height
Total
Volume
of
Excavated
Soil
Surface
Area
of
Each
Basin
Face
Volume
of
Soil
Used
in
Embankments/
Berms
3)
Calculate
and
sum
the
capital
and
O&
M
costs
for
constructing
the
storage
pond.

Capital
Costs
=
mobilization
+
excavation
+
compaction
+
conveyance
see
Table
5.5.3­
1
in
the
"
Assumptions"
worksheet
for
unit
costs
Annual
O&
M
Costs
=
5%
x
Capital
Cost
4)
Calculate
the
capital
and
O&
M
costs
for
solids
separation
in
wet
layer
farms.
(
Cost
Report
Section
5.7)

Capital
Costs
=
6
months
of
solids
volume
x
safety
factor
x
storage
tank
cost)
+
separator
device
+
(
pipe
length
x
pipe
cost)
+
(
installation
labor
x
labor
rate)

Annual
O&
M
Costs
=
2%
x
capital
cost
5)
Annualize
storage
pond
and
solids
separation
costs
for
each
animal
sector.

6)
Convert
Annual
Storage
Pond
Cost
to
a
"
per
ton
of
manure"
basis
which
can
be
added
to
the
Poultry
Composting
Report
Table
15
costs
per
ton
of
manure.
Convert
1997$

The
final
costs
of
composting
with
runoff
storage
ponds
will
be
incorportated
into
ERG's
CAFO
cost
database
and
applied
to
the
model
farms
developed
for
all
CAFO
Option
calculations.
7$
to
2001$
Assumptions:

Variable
Assumption
Value
Unit
Notes
Wet
Layer
Storage
Ponds
Wet
layer
operations
already
have
storage
ponds
in
place
and
do
not
need
to
be
costed
for
additional
storage
for
compost
runoff.

Wet
layer
waste
needs
to
undergo
solids
separation
before
composting.
Solids
separation
costs
were
not
originally
included
in
the
composting
costs
from
the
Poultry
Composting
Report.

Therefore,
solids
separation
costs
are
calculated
in
this
spreadsheet
and
included
in
the
final
composting
cost
for
wet
layers.

Costs
and
characteristics
for
wet
layer
waste
solids
separation
are
comparable
to
swine
costs.
Layer
solids
separation
was
not
costed
in
the
original
Cost
Report.)
The
Poultry
Composting
Report
(
p.
6)
describes
a
solids
separation
step
with
the
same
separator
efficiency
(
30%)
and
final
solids
content
(
23%)
for
wet
layers
as
the
swine
conditions
set
in
the
Cost
Report
(
p.
5­
75)

Wet
Layer
manure
moisture
content
75%
Poultry
Composting
Report
p.
6
Wet
Layer
solids
separator
efficiency
30%
Poultry
Composting
Report
p.
6
Sludge
Accumulation
­

Layer
0.0295
cf/
lb
Sludge
Accumulation
­

Broiler
0.455
cf/
lb
Sludge
Accumulation
­

Turkey
There
is
no
NRCS
data
for
turkey
sludge
accumulation,
so
it
is
assumed
that
turkey
compost
has
the
same
sludge
accumulation
rate
as
broilers
since
similar
manure
management
practices
are
used
for
both.
0.455
cf/
lb
Proportion
of
Runoff
that
is
solids
1.5%
Cost
Report
p.
4­
77.
The
mixed
compost
material
has
about
60%
moisture
content.
Dairy
cattle
manure
has
about
88%

moisture
content.
Using
the
cattle
proportion
of
solids
in
runoff
for
poultry
composting
operations
will
underestimate
the
solids
content
in
runoff,

lowering
the
amount
of
necessary
sludge
storage.
This
is
a
conservative
estimate
for
CAFO
costs.

Amount
of
Precipitation
that
will
Runoff
40.0%
Cost
Report
p.
4­
74.
This
estimate
assumes
that
the
drylots
are
20%
paved.
Our
poultry
composting
model
uses
unpaved
composting
area
which
will
have
less
runoff
and
decrease
the
storage
pond
size.

So
this
estimate
is
aggressive
in
that
it
will
result
in
slightly
higher
CAFO
costs
to
build
storage
ponds.

Wet
Layer
Solids
Separation
poultry
composting
area
runoff
has
the
same
characteristics
as
dairy
cattle
feedlot
runoff.
Natural
Resources
Conservation
Service's
Agricultural
Waste
Management
Field
Handbook,

1992.
From
web
page
<
http://
ianrpubs.
unl.
edu/
wastemg
t/
g1371.
htm>
11/
15/
05
(
same
source
used
in
the
Cost
Report
p.
5­
57)

Sludge
accumulation
ratio
for
animal
manure
compost
is
the
same
as
it
would
be
for
plain
manure
for
that
animal.
Pond
Volume
needs
180
days
(
6
months)
of
storage
capacity
Cost
Report
p.
5­
57
Height
of
embankment
around
each
storage
pond
3
feet
Width
of
embankment
base
around
each
storage
pond
6
feet
Type
of
Compost
Ammendment
used
throughout
Industry
Industry
would
use
the
cheaper
ammendment
assuming
that
all
compost
ammendments
are
equally
available.
Lacking
data
to
show
the
availablility
of
different
compost
ammendments,
ERG
selected
the
less
expensive
composting
option
by
ammendment
(
sawdust)
to
calculate
the
final
annual
cost
for
each
industry
sector.
(
See
"
Input
to
Database"

worksheet.)

Layer
Wet
Manure
Weight
The
Poultry
Composting
Report
gives
annual
wet
manure
production
in
gallons,
which
we
want
to
convert
to
pounds.
USDA
data
source
suggests
that
wet
layers
produce
60.5
pounds
of
manure,
which
is
equivalent
to
0.93
cubic
feet,
per
day
per
1000
pounds
of
live
animal
weight.
This
weight
to
volume
ratio
was
adjusted
to
a
"
pounds
per
gallon"
conversion
factor.
8.696423215
pounds/
gallon
Ag
Waste
Management
Field
Handbook.
USDA.
1996.

Chapter
4,
p.
414.

Precipitation
Estimates
Region
Wettest
6­
Month
Precipitation
(
in)
25­
Year,
24­
Hour
Precipitation
(
in)
10­
year,
1­
Hour
Precipitation
(
in)
10­
year,
10­
day
Precipitation
(
in)
Annual
Evaporation
(
in)

Central
6.65
4
1
7
49
Mid­
Atlantic
21.52
5.4
2.1
9
32
Midwest
11.2
5
2
7
36
Pacific
23.25
10
1.6
6
37
South
25.59
8
3
12
45
(
data
from
Table
4.7.1­
1
and
ERG
Beef/
Dairy
Cost
Model
<
Precipitation
Tables>
THESE
ARE
ESTIMATES
FOR
"
ALL
ANIMAL
GROUPS")

Storage
Pond
Unit
Costs
Unit
Cost
(
1997
dollars)
per
Source
Mobilization
$
205.00
event
Means
1999
(
022
274
0020)
a
Excavation
$
2.02
cubic
yard
Means
1999
(
022
238
0200)
a
Compaction
$
0.41
cubic
yard
Means
1996
(
022
226
5720)
a
Conveyance
$
7,644.00
event
ERG,
2000c
(
data
from
Table
5.5.3­
1)

Poultry
Composting
Report
Model
Farms
Sector
Region
#
Head
Manure
Produced
per
Year
(
tons)
Manure
Ammendments
Compost
Mix
Volume
(
cu
yd)
Windrow
Length
(
ft)
Windrow
Area
(
acres)
Windrow
Area
(
sq
ft)
Total
Annualized
Cost
per
Incoming
Manure
(
1997$/
ton)

Layer:
Wet
South
3,654
149
wheat
straw
&
sawdust
550
619
0.0928
4,042
$
36.51
Layer:
Wet
Sawdust
South
3,654
149
sawdust
402
453
0.0715
3,115
$
18.63
Layer:
Dry
South
884,291
6,838
wheat
straw
142,727
190,608
24.0815
1,048,990
$
229.79
Layer:
Dry
Sawdust
South
884,291
6,838
sawdust
65,100
88,561
11.195
487,654
$
49.30
Broiler
Mid­
Atlantic
36,796
587
wheat
straw
5,632
7,841
1.0045
43,756
$
91.65
Broiler
Sawdust
Mid­
Atlantic
36,796
587
sawdust
2,781
4,093
0.5306
23,113
$
19.81
Turkey
Mid­
West
158,365
9,691
wheat
straw
61,758
84,666
10.7043
466,279
$
46.34
Turkey
Sawdust
Mid­
West
158,365
9,691
sawdust
40,266
56,455
7.1424
311,123
$
11.05
(
From
Poultry
Composting
Report
Tables
2,
4,
6,
&
15)

Embankment
dimensions
(
around
the
storage
ponds)
are
the
same
as
typical
"
berm"
dimensions
that
are
used
to
contain
stromwater
runoff.
Cost
Report
p.
5­
19
Storage
Pond
Cost
Calculations:

1)
Determine
necessary
pond
volume.

Cost
Report
page
p.
5­
57
p.
4­
74
p.
4­
75
Variable
Runoff
Solids
(
lb)
Sludge
Volume
(
cf)
Regular
Runoff
(
cf)
Design
Storm
Runoff
(
cf)

Equation
total
runoff
volume
(
cf)
x
Density
of
Water
(
62.4
lb/
cf)
x
%
solids
Sludge
Accumulation
x
Runoff
Solids
%
Runoff
from
Composting
Area
x
Avg.
6­
month
Precipitation
(
ft)
x
composting
area
(
sq.
ft)
(
Precipitation
(
ft)
­
0.5)
x
composting
area
(
sq.
ft)
Layer:
Dry
1,450,854
42,800
894,789
655,269
Layer:
Dry
Sawdust
674,473
19,897
415,969
304,621
Broiler
46,089
20,970
31,388
17,852
Broiler
Sawdust
24,345
11,077
16,580
9,430
Turkey
326,455
148,537
174,078
174,699
Turkey
Sawdust
217,826
99,111
116,153
116,567
2)
Calculate
dimensions
and
configuration
of
pond.

Dimensions
needed
for
Cost
Calculations
Sector
Total
Pond
Volume
(
cu
ft)
Height/
Depth
(
ft)
Slope
Base
Length
&
Width
(
ft)
Layer:
Dry
1,962,953
10
2
423
Layer:
Dry
Sawdust
919,073
10
2
283
Broiler
91,554
10
2
75
Broiler
Sawdust
49,726
10
2
50
Turkey
551,652
10
2
215
Turkey
Sawdust
369,221
10
2
172
3)
Calculate
and
sum
the
capital
and
O&
M
costs
for
constructing
the
storage
pond.
Capital
Costs
=
mobilization
+
excavation
+
compaction
+
conveyance
Annual
O&
M
Costs
=
5%
x
Capital
Cost
(
excluding
conveyance)

Cost
of
Storage
Pond
for
Each
Model
Farm
(
1997$)
Sector
Conveyance
Mobilization
Excavation
Compaction
Layer:
Dry
$
7,644
$
205
$
462,603
$
10,685
Layer:
Dry
Sawdust
$
7,644
$
205
$
216,595
$
5,435
Broiler
$
7,644
$
205
$
21,576
$
931
Broiler
Sawdust
$
7,644
$
205
$
11,719
$
651
Turkey
$
7,644
$
205
$
130,006
$
3,520
Turkey
Sawdust
$
7,644
$
205
$
87,013
$
2,538
4)
Calculate
the
capital
and
O&
M
costs
for
solids
separation
in
wet
layer
model
farms.

6
mo.
solids
volume=
(
annual
manure
generation
(
gallons)
*
%
solids
of
manure
*
%
efficiency
of
separation
=
1,287
gallons
Capital
Costs
=
6
months
of
solids
volume
x
safety
factor
x
storage
tank
cost)
+
separator
device
+
(
p
=
$
28,839.00
Annual
O&
M
Costs
=
2%
x
capital
cost
=
$
576.78
5)
Calculate
Annualized
Cost
Annualization
of
Storage
Pond
or
Solids
Separation
Costs
1
2
3
4
Layer:
Wet
$
29,127
$
577
$
577
$
577
Layer:
Wet
Sawdust
$
29,127
$
577
$
577
$
577
Layer:
Dry
$
492,974
$
23,675
$
23,675
$
23,675
Layer:
Dry
Sawdust
$
235,435
$
11,112
$
11,112
$
11,112
Broiler
$
30,924
$
1,136
$
1,136
$
1,136
Broiler
Sawdust
$
20,533
$
629
$
629
$
629
Turkey
$
144,718
$
6,687
$
6,687
$
6,687
Turkey
Sawdust
$
99,644
$
4,488
$
4,488
$
4,488
6)
Convert
Annual
Storage
Pond
Cost
to
a
"
per
ton
of
manure"
and
Add
to
T­
T
Memo
C
1997$
2001$

Sector
Manure
Produced
per
Year
(
tons)
Annual
Cost
of
Pond
or
Solids
Separation
per
Ton
Manure
($/
ton)
Total
Cost
of
Composting
with
Runoff
Storage
Pond
(
1997$/
ton)
Total
Cost
of
Composting
with
Runoff
Storage
Pond
(
2001$/
ton)
Layer:
Wet
149
$
27.58
$
64.09
$
69.20
Layer:
Wet
Sawdust
149
$
27.58
$
46.21
$
49.89
Sector
Layer:
Dry
6,838
$
11.91
$
241.70
$
260.98
Layer:
Dry
Sawdust
6,838
$
5.66
$
54.96
$
59.35
Broiler
587
$
8.20
$
99.85
$
107.81
Broiler
Sawdust
587
$
5.26
$
25.07
$
27.07
Turkey
9,691
$
2.44
$
48.78
$
52.68
Turkey
Sawdust
9,691
$
1.67
$
12.72
$
13.74
p.
4­
72
p.
5­
59
Net
Precipitation
(
ft)
Design
Storm
Precipitation
(
ft)
Pond
Volume
for
Runoff
and
Sludge
Only
Volume
of
Freeboard
+
Net
Precipitation
+
Design
Storm
Precipitation
(
cf)

Avg.
6­
month
Precipitation
­
(
Annual
Evaporation/
2)
<
feet
of
precipitation
that
will
fall
into
the
pond>
Sludge
Volume
+
Runoff
+
Design
Storm
Runoff
(
Pond
Top
Area
(
sq
ft)
x
1
ft)
+
(
Pond
Top
Area
x
Net
Precipitation)
+
(
Pond
Top
Area
x
Design
Storm
Precipitation)
0.258
0.667
1,592,858
370,095
0.258
0.667
740,487
178,585
0.460
0.450
70,210
21,344
0.460
0.450
37,087
12,639
­
0.567
0.417
497,314
54,338
­
0.567
0.417
331,831
37,390
Depth
(
all)
=
9
ft
Slope
(
all)
=
2
Top
Length
and
Width
(
ft)
Layer:
Dry
439
Layer:
Dry
Sawdust
305
Broiler
106
Broiler
Sawdust
81
Turkey
253
Turkey
Sawdust
210
p.
5­
62
p.
5­
61
Top
Length
&
Width
(
ft)
Surface
Area
of
Basin
(
sq
ft)
Volume
of
Embankment
(
cu
ft)
Total
Volume
of
Excavated
Soil
(
cu
ft)
463
196,562
37,980
2,061,101
323
92,174
27,134
965,026
115
9,422
11,019
96,132
90
5,239
9,050
52,212
255
55,432
21,837
579,235
212
37,189
18,522
387,682
Pond
Dimensions
without
Freeboard
(
calculated
using
the
Cost
Model
method)
Capital
Cost
O&
M
$
481,136
$
23,675
$
229,879
$
11,112
$
30,357
$
1,136
$
20,219
$
629
$
141,375
$
6,687
$
97,400
$
4,488
s.

tion)/
2
(
pipe
length
x
pipe
cost)
+
(
installation
labor
x
labor
rate)

5
6
7
8
$
577
$
577
$
577
$
577
$
577
$
577
$
577
$
577
$
23,675
$
23,675
$
23,675
$
23,675
$
11,112
$
11,112
$
11,112
$
11,112
$
1,136
$
1,136
$
1,136
$
1,136
$
629
$
629
$
629
$
629
$
6,687
$
6,687
$
6,687
$
6,687
$
4,488
$
4,488
$
4,488
$
4,488
o
Costs.
Convert
to
final
cost
to
2001$.
Year
Total
Pond
Volume
(
cu
ft)

Sludge
Volume
+
Runoff
+
Net
Precipitation
+
Design
Storm
+
Freeboard
1,962,953
919,073
91,554
49,726
551,652
369,221
9
10
11
$
577
$
577
$
288
$
30,871
$
4,117
$
577
$
577
$
288
$
30,871
$
4,117
$
23,675
$
23,675
$
11,837
$
610,502
$
81,415
$
11,112
$
11,112
$
5,556
$
290,332
$
38,718
$
1,136
$
1,136
$
568
$
36,086
$
4,812
$
629
$
629
$
314
$
23,167
$
3,090
$
6,687
$
6,687
$
3,343
$
177,554
$
23,678
$
4,488
$
4,488
$
2,244
$
121,517
$
16,205
Annualized
Cost
(
1997$)
Net
Present
Value
For
volumes
>
9,216
cubic
feet,
the
length
and
side
slope
are:
(
from
Table
5.4.5­
3
in
Cost
Model
Report)

Lagoon
Sizing
Equations
1.
Tetra
Tech
Equations
(
pg
5­
49)
W
lagoon
bottom
=
[(­
2(
h^
2)*
s)+
((
4*(
h^
4))*
s^
2))­
4*
h*((
4/
3)*(
h^
3)*(
s^
3)­
Vo
W
lagoon
bottom
=
L
lagoon
bottom
W
lagoon
top
=
W
lagoon
bottom
+(
2*
s*
depth)
L
lagoon
top
=
L
lagoon
bottom
+(
2*
s*
depth)

Where
W
lagoon
bottom
=
width
of
bottom
of
lagoon,
ft
W
lagoon
top
=
width
of
top
of
lagoon,
ft
L
lagoon
bottom
=
length
of
bottom
of
lagoon,
ft
L
lagoon
top
=
length
of
top
of
lagoon,
ft
s
=
slope
of
sidewalls,
ft
h
=
depth
of
lagoon,
ft
2.
Frustrum
Equation
(
pg
5­
46)
Volume
=
(
1/
3)
*
h
*
(
ab+
cd+(
abcd^(
1/
2)))

Where
h
=
Height
a
=
b
=
Length
and
width
of
lagoon
top
c
=
d
=
Length
and
width
of
lagoon
bottom
L
and
W
calculated
using
Equation
1
and
checked
with
Equation
2
from
Volume
worksheet
Check
of
Volume
with
equation
2
(
fulstrum
eqn)

Volume
Storage,
ft3
L
and
W
lagoon
bottom,
ft
L
and
W
lagoon
top,
ft
Volume
Calculated
from
bottom
L
and
W,
ft3
Layer:
Dry
1,592,858
402.5665
439
1,592,858
Layer:
Dry
Sawdust
740,487
268.6503
305
740,487
Broiler
70,210
69.7107
106
70,210
Broiler
Sawdust
37,087
45.3463
81
37,087
Turkey
497,314
216.8385
253
497,314
Turkey
Sawdust
331,831
173.7344
210
331,831
scenario
equation
1
(
Tetra
Tech)
Depth
Slope
9
2
Volume
storage))^
0.5]/
2h
For
volumes
>
9,216
cubic
feet,
the
length
and
side
slope
are:
(
from
Table
5.4.5­
3
in
Cost
Model
Report)

Lagoon
Sizing
Equations
1.
Tetra
Tech
Equations
(
pg
5­
49)
W
lagoon
bottom
=
[(­
2(
h^
2)*
s)+
((
4*(
h^
4))*
s^
2))­
4*
h*((
4/
3)*(
h^
3)*(
s^
3)­
Vo
W
lagoon
bottom
=
L
lagoon
bottom
W
lagoon
top
=
W
lagoon
bottom
+(
2*
s*
depth)
L
lagoon
top
=
L
lagoon
bottom
+(
2*
s*
depth)

Where
W
lagoon
bottom
=
width
of
bottom
of
lagoon,
ft
W
lagoon
top
=
width
of
top
of
lagoon,
ft
L
lagoon
bottom
=
length
of
bottom
of
lagoon,
ft
L
lagoon
top
=
length
of
top
of
lagoon,
ft
s
=
slope
of
sidewalls,
ft
h
=
depth
of
lagoon,
ft
2.
Frustrum
Equation
(
pg
5­
46)
Volume
=
(
1/
3)
*
h
*
(
ab+
cd+(
abcd^(
1/
2)))

Where
h
=
Height
a
=
b
=
Length
and
width
of
lagoon
top
c
=
d
=
Length
and
width
of
lagoon
bottom
L
and
W
calculated
using
Equation
1
and
checked
with
Equation
2
from
Volume
worksheet
Check
of
Volume
with
equation
2
(
fulstrum
eqn)

Volume
Storage,
ft3
L
and
W
lagoon
bottom,
ft
L
and
W
lagoon
top,
ft
Volume
Calculated
from
bottom
L
and
W,
ft3
Layer:
Dry
1,962,953
422.9018
463
1,962,953
Layer:
Dry
Sawdust
919,073
282.9421
323
919,073
Broiler
91,554
74.9847
115
91,554
Broiler
Sawdust
49,726
49.5646
90
49,726
Turkey
551,652
214.5888
255
551,652
Turkey
Sawdust
369,221
171.8040
212
369,221
scenario
equation
1
(
Tetra
Tech)
Depth
Slope
10
2
Volume
storage))^
0.5]/
2h
Sector
Region
#
Head
Manure
Produced
per
Year
(
tons)
Layer:
Wet
South
3,654
149
Layer:
Dry
South
884,291
6,838
Broiler
Mid­
Atlantic
36,796
587
Turkey
Mid­
West
158,365
9,691
Total
Cost
of
Composting
with
Runoff
Storage
Pond
(
2001$/
ton)
$
49.89
$
59.35
$
27.07
$
13.74