United States
Environmental Protection
Agency
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U.S. Environmental Protection Agency
Office of Water (4303T)
1200 Pennsylvania Avenue, NW
Washington, DC 20460
EPA-821-R-03-004
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Cost Methodology for the Final Revisions to the National Pollutant
Discharge Elimination System Regulation and the Effluent
Guidelines for Concentrated Animal Feeding Operations
Christine Todd Whitman
Administrator .....
G. Tracy Mehan III
Assistant Administrator, Office of Water
Sheila E. Frace
Director, Engineering and Analysis Division
Paul H. Shriner
Project Manager
Ronald Jordan
Technical Coordinator
Engineering and Analysis Division
Office of Science and Technology
U.S. Environmental Protection Agency
Washington, D.C. 20460
December 2002
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ACKNOWLEDGMENTS AND DISCLAIMER
This report was prepared by Eastern Research Group, Inc., under the direction and
review of the Office of Science and Technology.
Neither the United States government nor any of its employees, contractors,
subcontractors, or other employees makes any warranty, expressed or implied, or
assumes any legal liability or responsibility for any third party's use of, or the results
of such use of, any information, apparatus, product, or process discussed in this
report, or represents that its use by such a third party would not infringe on privately
owned rights.
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TABLE OF CONTENTS
1.0
2.0
3.0
Page
INTRODUCTION j_j
1.1 Regulatory Options j_j
1.2 Model Farm Descriptions l_g
1.2.1 Beef Feedlots and Heifer Operations '....' i_g
1.2.2 Dairies J_JQ
1.2.3 Veal Operations .;...' 1-14
1.2.4 Swine Operations 1_15
1.2.5 Poultry Operations 1_19
1.3 Key Terms j_22
1.3.1 Size Groups ' l_23
1.3.2 Frequency Factors 1_23
' "•" 1.3.3 Manure and Waste 1_26
1.4 Organization of Report j_26
1.5 References 1-27
COST MODEL STRUCTURE 2-i
2.1 Beef and Dairy Cost Model 2-1
2.1.1 Input Data to Cost Model 2-4
2.1.2 Technology Calculations 2-5
2.1.3 Frequency Factors 2-7
2.1.4 Calculation of Weighted Costs 2-8
2.2 Swine and Poultry Cost Model 2-10
2.2.1 Input Data to Cost Model '...'.'.'.'.'.'.'.'.'. 2-13
2.2.2 Technology Calculations 2-15
2:2.3 Frequency Factors 2-18
2.2.4 Calculation of Weighted Costs 2-20
2.3 References 2_2l
DATA SOURCES * 3-1
3.1 Summary of EPA's Site Visit Program '.'.'.'.'.'.'.'.'.'. 3-1
3.2 Industry Trade Associations \\ 3.3
3.3 U.S. Department of Agriculture (USDA) .!..'. 3-5
3.3.1 National Agricultural Statistics Service (NASS) 3-6
3.3.2 Animal and Plant Health Inspection Service (APHIS)/National
Animal Health Monitoring System (NAHMS) 3-10
3.3.3 Natural Resources Conservation Services (NRCS) 3-13
3.3.4 Agricultural Research Service (ARS) 3.14
3.3.5 Economic Research Service (ERS) 3.15
3.4 Literature Sources 3_j5
3.5 National Climate Data Center (NCDC) ... 3.15
3.6 References 3-16
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r
TABLE OF CONTENTS (Continued)
Page
4.0
INPUT DATA -
4.1 Definition of Regions 4-1
4.2 Definition of Size Groups •• • '• 4-5
4.3 Farm Counts • 4-5
4.3.1 Farm Counts - Beef Feedlots : 4-6
4.3.2 Farm Counts - Dairies ... •> 4-9
4.3.3 Farm Counts - Heifer Operations 4-12
4.3.4 Farm Counts - Veal Operations • • - 4-14
4.3.5 Farm Counts - Poultry Operations .. . . • • • 4-16
4.3.6 Farm Counts - Swine Operations .. • • • • • • • • 4-37
4.4 'Average Head .'. .".'.. '.'.. -. 4-46
4.4.1 Average Head - Beef Feedlots 4-46
4.4.2 Average Head - Dairies 4-47
4.4.3 Average Head - Heifer Operations 4-49
4.4.4 Average Head - Veal Operations 4-49
4.4.5 Average Head - Poultry Operations 4-50
4.4.6 Average Head - Swine Operations 4-55
4.5 Wastewater/Dilution Water 4-57
4.5.1 Wastewater Generation at Dairies 4-58
4.5.2 Wastewater Generation at Veal Operations 4-62
4.5.3 Wastewater and Dilution at Dry Poultry Operations 4-63
4.5.4 Wastewater and Dilution at Swine
and Wet Layer Operations • • 4-64
4.6 Manure Generation 4-65
4.6.1 Manure Generation at Beef Feedlots,
Heifer Operations, Dairies, and Veal Operations 4-65
4.6.2 Recoverable Manure Generation at Poultry Operations 4-68
4.6.3 Recoverable Manure Generation at Swine Operations 4-70
4.7 Precipitation Data and Runoff 4-71
4.7.1 Precipitation Estimates 4-73
4.7.2 Drylot Area Estimates 4-74
4.7.3 Total Runoff 4-75
4.7.4 Runoff Solids • • • 4-78
4.8 Crops and Agronomic Application Rates 4-79
4.9 Excess Manure, 4-80
4.9.1 Beef and Dairy 4-84
4.9.2 Poultry and Swine '• 4-86
4.10 Acres • 4-91
4.10.1 Total Available Cropland Acres at Beef Feedlots,
Dairies, Heifer and Veal Operations and Category 1
Swine and Poultry Acreage 4-92
4.10.2 Swine and Poultry Operations 4-107
11
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5.0
TABLE OF CONTENTS (Continued)
Page
4.11 References 4-107
TECHNOLOGY COST EQUATIONS , 5-1
5.1 Earthen Settling Basins 5-1
511.1 Technology Description 5-2
5.1.2 Design 5-2
5.1.3 Costs 5-9
5.1.4 Results 5-10
5.2 Concrete Settling Basins 5-10
5.2.1 Technology Description . .-. .T...... 5-11
5.2.2 Design 5-11
5.2.3 Costs ' 5-15
5.2.4 Results 5-18
5.3 Berms , 5-18
5.3.1 Technology Description 5-18
5.3,2 Design 5-19
5.3.3 Costs 5-22
5.3.4 Results 5-24
5.4 Lagoons 5-25
5.4.1 Technology Description 5-26
5.4.2 Design of Anaerobic Lagoons
at Dairies and Veal Operations 5-27
5.4.3 Costs for Constructing a Dairy Lagoon 5-39
5.4.4 Dairy Lagoon Results 5-43
5.4.5 Design of Lagoons and Evaporative Ponds for
Swine and Poultry Operations . 5-43
5.4.6 Costs for Lagoons at Swine and Poultry Operations 5-52
5.5 Ponds . 5-52
5.5.1 Technology Description 5-53
5.5.2 Design 5-54
5.5.3 Costs , 5-63
5.5.4 Results 5-67
5.6 Nutrient Management 5-67
5.6.1 Nutrient Management Plan Development
and Associated Costs 5-67
5.6.2 Soil Sampling 5-68
5.6.3 Manure Sampling 5-69
5.6.4 Recordkeeping and Reporting 5-70
5.6.5 Commercial Nitrogen Fertilizer 5-71
5.6.6 Lagoon Depth Marker 5-71
5.6.7 Establishment of Setback Areas 5-72
5.6.8 Manure Spreader Calibration 5-73
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TABLE OF CONTENTS (Continued)
Page
5.7 Screen Solid-Liquid Separation for Swine Operations 5-74
5.7.1 Technology Description and Design 5-75
5.7.2 Costs 5-75
5.8 Land Application 5-76
5.8.1 Center Pivot Irrigation 5-77
5.8.2 Traveling Gun Irrigation 5-79
5.8.3 Beef and Dairy Irrigation Costs 5-81
5.9 Transportation ; 5-83
5.9.1 Technology Description 5-83
5.9.2 Design and Costs of Contract Hauling 5-85
5.9.3 Design and Cost of Purchase Equipment
Transportation Option 5-89
5.9.4 Transportation Cost Test 5-94
5.9.5 Results 5-96
5.10 Ground-Water Assessment and Monitoring 5-96
5.10.1 Technology Description , 5-96
5.10.2 Design and Costs 5-97
5.10.3 Results 5-100
5.11 Concrete Pads 5-100
5.11.1 Description of Concrete Pads 5-100
5.11.2 Design 5-101
5.11.3 Costs 5-107
5.11.4 Results 5-109
5.12 Composting ' 5-109
5.12.1 Technology Description : . 5-110
5.12.2 Design 5-111
5.12.3 Costs - 5-116
5.12.4 Results - 5-119
5.13 Anaerobic Digestion with Energy Recovery 5-119
5.13.1 Technology Description 5-120
5.13.2 Design - 5-122
5.13.3 Costs , 5-124
5.13.4 Results ..: 5-127
5.14 Litter Storage Sheds 5-127
5.15 Lagoon Covers 5-129
5.16 Feeding Strategies . 5-132
5.16.1 Technology Description 5-132
5.16.2 Costs i 5-133
5.17 Options to Retrofit Swine and Wet Layer Systems
to Dry Systems 5-139
5.17.1 Lagoon Cleanout and Closure Costs : 5-140
5.17.2 Retrofit to Scraper System 5-141
IV
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TABLE OF CONTENTS (Continued)
6.0
7.0
Page
8.0
5.17.3 Retrofit to High Rise Hog Houses 5-144
5.17.4 Retrofit to Hoop Houses 5-145
5.18 Recycling of Flush Water . 5-146
5.19 Sludge Cleanout 5-147
5.19.1 Technology Description 5-148
5.20 Surface Water Monitoring 5-150
5.20.1 Practice Description 5-150
5.20.2 Prevalence of the Practice in the Industry 5-151
5.20.3 Design 5-151
5.20.4 Costs ; 5-152
5.20.5 Results 5-153
5.21 References 5-153
FREQUENCY FACTORS 6-1
6.1 Beef and Dairy Technology Frequency Factors 6-2
6.1.1 Performance-Based Frequency Factors
Based on USDA Data 6-3
6.1.2 Other Performance-Based Frequency Factors 6-15
6.1.3 Other Technology Frequency Factors 6-16
6.2 Beef and Dairy Nutrient Basis Frequency Factors 6-19
6.3 Beef and Dairy Land Availability Frequency Factors 6-21
6.4 Poultry and Swine Technology Frequency Factors . . 6-25
6.5 Poultry and Swine Nutrient Basis Frequency Factors 6-38
6.6 Poultry and Swine Land Availability Frequency Factors 6-40
6.7 Ground Water Control Frequency Factors 6-42
6.8 References 6.45
EXAMPLE MODEL CALCULATIONS 7.1
7.1 Beef and Dairy Model Farm Example Calculation 7-1
7.1.1 Unit Component Costs 7-2
7.1.2 Calculation of Weighted Component Costs 7-5
7.1.3 Calculation of Weighted Farm Costs 7-7
7.1.4 Final Model Farm Costs 7-11
7.2 Swine and Poultry Model Farm Cost Example 7-12
7.2.1 Unit Component Costs 7-13
7.2.2 Calculation of Adjusted Component Costs 7-20
7.2.3 Calculation of Weighted Farm Costs
by Nutrient Application Basis for Option 2 7-27
7.2.4 Final Model Farm Costs 7-28
SENSITIVITY ANALYSES 8-1
8.1 Option 1A . . . 8_2
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8.2
8.3
8.4
8.5
8.6
TABLE OF CONTENTS (Continued)
Page
Cost Driver Analysis 8-3
Option 2A 8-4
Option 2B , . 8-5
Applications to Frozen Ground .. 8-6
References • 8-9
A
B
LIST OF APPENDICES
Unweighted Component Costs
Selected Transportation Option for Options 1 and 2 for Beef Feedlots, Dairies, and
Heifer Operations .
Model Farm Costs for Options 1, 2 and 5
VI
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LIST OF TABLES
Page
1.1-1 Summary of Regulatory Options 1-4
1.2.4-1 Model Swine Farms by Farm Type, Size, Region,
and Waste Storage System 1_19
1.2.5-1 Model Poultry Farms by Farm Type, Size, and Region 1-22
1.3-1 Size Classes for Model Farms 1-23
2.1-1 Beef and Dairy Model Farm Records 2-3
2.1.2-1 Waste Management Technologies for Beef Feedlots, Dairies,
and Heifer and Veal Operations 2-5
2.2.1-1 Swine and Poultry Model Farm Input Records 2-16
3-1 Number of Site Visits Conducted by EPA for the
Various Animal Industry Sectors 3-2
4.1-1 Animal Feeding Operation (AFO) Production Regions 4-2
4.1-2 Key Regions Modeled by Animal Sector 4.4
4.2-1 Size Classes for Model Farms3 4.5
4,3.1 -1 Number of Potential Beef CAFOs by EPA Size Class
From the 1997 Census of Agriculture Database 4-7
4.3.1-2 Percentage of Beef Feedlots by Region and
Census of Agriculture Size Category 4.7
4.3.1-3 Number of Beef Feedlots by Region and Size Class 4-8
4.3.1-4 Percentage of Beef Facilities That Are Expected to Be CAFOs 4-9
4.3.2-1 Number of Potential Dairy CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database 4-10
4.3.2-2 Percentage of Dairies by Region and
Census of Agriculture Size Category 4.10
4.3.2-3 Number of Dairies by Region and Size Class 4-11
vn
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LIST OF TABLES (Continued)
Page
4.3.2-4 Percentage of Dairies That Are Expected to Be CAFOs . 4-11
4.3.3-1 Number of Potential Heifer CAFOs by EPA Size Class
from the 1997 "Census of Agriculture Database 4-12
4.3.3-2 Percentage of Heifer Operations by Region and Size Class 4-13
4.3.3-3 Number of Heifer Operations by Region and Size Class 4-14
4.3.3-4 Percentage of Heifer Operations That Are Expected to Be CAFOs 4-14
4.3.4-1 Number of Potential Veal CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database 4-15
4.3.4-2 Percentage of Veal Operations by Region and Size Class 4-15
4.3.4-3 Number of Veal Operations by Region and Size Class 4-16
4.3.4.4 Percentage of Veal Operations That Are Expected to Be CAFOs 4-16
4.3.5-1 Number of Layer Operations by EPA Size Class from
the 1997 Census of Agriculture .Database • • 4-17
4.3.5-2 Number of Layer Operations by Size Class and Region
from 1997 Census of Agriculture Database 4-18
4.3.5-3 Reorganized Layer and Pullet Operation Counts 4-18
4.3.5-4 Reorganized Distribution of Dry Layer, Wet Layer,
and Pullet Operations by Region 4-19
4.3.5-5 Reorganized Distribution of Dry Layer, Wet Layer,
and Pullet Operations 4-20
4.3.5-6 Intermediate Layer Operation Counts by Sector, Size Class,
and Region 4-22
4.3.5-7 Final Layer Operation Counts by Sector, Size Class,
and Region 4-23
4.3.5-8 Final Layer Operation Counts by Sector, Size Class,
vui
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LIST OF TABXLES (Continued)
••-•••• Page
and Modeled Region 4-24
4.3.5-9 Percentage of Layer Operations That Are
Expected to Be CAFOs 4-24
4.3.5r10 Percentage of Dry Layer Operations That Are ' ..
Expected to Be CAFOs 4-25
4.3.5-11 Number of Turkey Operations by Size Class from
1997 Census of Agriculture Database . 4-25
4.3.5-12 Number of Turkey Operations by Size Class and Region
from 1997 Census of Agriculture Database 4-26
4.3.5-13 Reorganized Turkey Operation Counts 4-27
4.3.5-14 Final Turkey Operation Counts by Size Class and Region 4-27
4.3.5-15 Final Turkey Operation Counts by Size Class
and Modeled Region :.... 4-28
4.3.5-16 Percentage of Turkey Operations That Are
Expected to Be CAFOs 4_28
4.3.5-17 Number of Broiler Operations as Provided by USDA NRCS (2002)
Based on Analyses of 1997 Census of Agriculture Database 4-29
4.3.5-18 Intermediate Number of Broiler Operations Based on Location,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure 4-32
4.3.5-19 Intermediate Number of Broiler Operations Based on Location,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure 4.33
4.3.5-20 Final Number of Broiler Operations Based on Region, Land Availability Category,
Operation Size for Nitrogen-Based Application of Manure 4-34
4.3.5-21 Final Number of Broiler Operations Based on Region, Land Availability Category,
Operation Size for Phosphorus-Based Application of Manure 4-35
4.3.5-22 Final Number of Broiler Operations Based on Modeled Region,
IX
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LIST OF TABLES (Continued)
4.3,5-23
4.3.5-24
4.3.6-1
4.3.6-2
4.3.6-3
4.3.6-4
4.3.6-5
4.3.6-6
4.3.6-7
4.3.6-8
4.4.1-1
4.4.2-1
Page
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure 4-36
Final Number of Broiler Operations Based on Modeled Region,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure 4-36
Percentage of Broiler Operations That Are Expected to Be CAFOs
4-37
Number of Swine Operations as Provided by USDA NRCS (2002)
Based on Analyses of 1997 Census of Agriculture Database 4-39
Intermediate .Number of Swine Operations Based on Location,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure • 4-40
Intermediate Number of Swine Operations Based on Location,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure 4-41
Final Number of Swine Operations Based on Region, Land Availability
Category, Operation Size for Nitrogen-Based Application of Manure 4-42
Final Number of Swine Operations Based on Region, Land Availability
Category, Operation Size for Phosphorus-Based Application of Manure 4-43
Final Number of Swine Operations -Based on Modeled Region,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure 4-44
Final Number of Swine Operations Based on Modeled Region,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure 4-44
Percentage of Swine Operations That Are Expected to Be CAFOs 4-45
Number of Fattened Cattle at Potential CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database 4-46
Number of Dairy Cows at Potential CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database 4-48
x
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LIST OF TABLES (Continued)
Page
4.4.3-1 Average Head for Heifer Model Farm .'.'.- 4.49
4.4.4-1 Average Head for Veal Model Farm 4_$0
4.4.5-1 Layer Facility Demographics from the 1997 Census of Agriculture
Database , 4.51
4.4.5-2 Average Head Count for Layer Operations 4-52
4.4.5-3 Turkey Facility Demographics from the 1997 Census of Agriculture
'Database ....' _ 4.53
4.4.5-4 Final Number of Broilers per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure , 4-54
4.4.5-5 Final Number of Broilers per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure 4.55
4.4.6-1 Final Number of Swine per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure 4.55
4.4.6-2 Final Number of Swine per Operation Based on Modeled Region, Land
Availability Category, Operation Size for Phosphorus-Based
Application of Manure .;..... 4-57
4.5.1-1 Milk Parlor Wastewater Generated at Dairies Using Hose Systems 4-58
4.5.1-2 Milk Parlor Wastewater Generated at Dairies Using Flush Systems 4-60
4.5.1-3 Wastewater Generation by Dairy Model Farm 4-62
4.5.2-1 Wastewater Generation by Veal Model Farm 4-63
4.6.1-1 Cattle Manure Production and Characteristics 4-66
4.6.1-2 Cattle Manure Generation by Model Farm 4.57
4.6.2-1 Poultry Manure Characteristics Used to Calculate Nutrient Production 4-68
XI
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(Continued)
...._. . ...—-™~,-. ,..,—.•• ,„', . • ,,: Page
4.6.2-2 Poultry Regional Recovery Factors for Manure 4-69
4.6.2-3 Example of Weighted Averaging Method for Manure
Recovery Factor 4-69
4.6.3-1 Swine Manure Characteristics Used to Calculate Nutrient Production 4-71
4.6.3-2 Swine Regional Recovery Factors for Manure 4-71
[_ _ . _,
4.7.1-1 Precipitation Estimates .".' ,-•••' 4-74
4.7.2-1 Drylot Area Required by Animal Typea • • 4-74
4.7.2-2 Drylot Area Required by Animal Type Used in the Cost Model 4-75
4.7.3-1 Six-Month Runoff Volumes , 4-76
4.7.3-2 25-Year, 24-Hour Rainfall Event Runoff Values . • j... 4-77
4.7.3-3 10-Year, 10-Day Rainfall Event Runoff Values 4-78
4.8-1 Beef and Dairy Crop Information 4-81
4.8-2 Total Crop Nutrient Requirements and Manure Application Rates 4-83
4.9.1-1 USDA Data on Manure Production at Livestock Facilities 4-85
4.9.1-2 Excess Manure Estimates by Animal Type and Size Class 4-86
4.9.2-1 On-Farm Acreage for Category 2 Layer and Turkey Operations 4-89
4.9.2-2 On-Farm Acreage with Manure Applied for Category 2
Broiler Operations 4-90
4.9.2-3 On-Farm Acreage with Manure Applied for Category 2
Swine Operations ....: 4-91
4.10.1-1 Category 1 and 2 Total Acreages
for Beef Feedlots, Dairies, Heifer and Veal Operations
Option2 4-95
4.10.1-2
Evapotranspiration Rate • 4-99
Xll
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LIST OF TABLES (Continued)
4.10.1-3
4.10.1-4
4.10.1-5
4.10.1-6
4.10.1-7 .
5.1.2-1
5.1.2-2
5.1.3-1
5.2.2-1
5.2.3-1
5.3.2-1
5.3.2-2
5.3.3-i
5.4.2-1
5.4.3-1
5.4.5-1
5.4.5-2
5.4.5-3
Page
1996 Average Regional Precipitation . A-S>9
Regional Soil Permeability . .. 4-100
• ''' ''' : -
Days of.Irrigation 4-101
Maximum Design Hydraulic Loading Rate Based on: Annual :
Permeability Evaluation ....:... 4-102
Minimum Number of Acres Required to Apply All Liquid at the
Hydraulic Loading Rate Under Option 2 4-104
Design Parameters for Earthen Basins 5.4
Earthen Basin Volume by Model Farm for All Regulatory Options 5-6
Unit Costs for Earthen Basins .muT ..... 5-9
Concrete Basin Volume by Model Farm for All Regulatory Options ....... 5-14
Unit Costs for Concrete Settling Basin 5.15
Space Requirements Assumed for Animals Housed on Drylots 5-20
Berm Perimeter by Beef and Dairy Model Farm for
All Regulatory Options 5.21
Unit Costs for Constructing Berms 5-23
Lagoon Storage Capacities at Dairies for Option 7 5-36
Unit Costs for Storage Lagoon 5.40
Chronic Rainfall Amounts for Option 1A for Swine and Poultry . 5-45
Relationships Among Depth, Side Slope, Volume, And Bottom
Width of Lagoons , 5.43
Depth and Side Slopes for Lagoons and Evaporative Ponds 5-49
xui
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LIST OF TABLES (Continued)
Page
5.5.2-1 Pond Storage Capacities at Beef Feedlot and Heifer Operations
for Option 7 • • • 5"57
5.5.3-1 Unit Costs for Storage Pond 5'64
5.6.5-1 Retail Cost of Nitrogen Fertilizer 5'71
5.8.3-1 Costs for Data Points from Center Pivot Irrigation Cost Curves 5-81
5.8.3-2 Costs for 250-gpm Liquid Applicators • • - • • 5'82
5.9.2-1 Hauling Distances for Transportation 5-87
5.9.2-2 Rates for Contract Hauling for Category 2 and 3 Beef Feedlots
andDairies 5'88
5.9.2-3 Hauling Rates for Category 2 and 3 Swine and Poultry Operations 5-88
5.11.3-1 Unit Costs for Concrete Pad 5-108
5.12.3-1 Unit Costs for Composting 5-117
5.13.2-1 FarmWare Input Table 5'123
5.13.2-2 FarmWare Design Information 5-124
5.13.3-1 Digester Costs for Swine 5-127
5.15-1 Manufacturer-Suggested Costs of Lagoon Covers for l/2- Acre Lagoons ... 5-131
5.16.2-1 Feeding Strategy Costs for Swine and Poultry • • 5-134
5.16.2-2 Crop Nutrient Uptake 5-136
5.20-1 Number of Samples 5'152
5.20-2 Capital Costs for Surface Water Sampling 5-152
5.20-3 Annual Costs for Surface Water Sampling 5-153
6.1.1-1 Correlation of EPA Beef Model Farm Components and
USDA Representative Farm Components 6-7
xiv
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LIST OF TABLES (Continued)
Page
6.1.1-2 Correlation of EPA Dairy Model Farm Components and
USDA Representative Farm Components ."'.'. .. 6-8
6.1.1-3 Percentage of EPA Beef Feedlots and Heifer Operations in
USDA Regions 6-9
6.1.1-4 Percentage of EPA Dairies in USDA Regions 6-10
6.1.1-5 Percentage of Beef Feedlots and Heifer Operations .Incurring
Earthen Basin Costs for All Regulatory Options 6-11
6.1.1-6 Beef Feedlots, Heifer Operations, and Dairies Incurring
Costs to Install and Maintain Berms for All Regulatory Options . 6-12
6.1.1-7 Beef Feedlots, Heifer Operations, and Dairies Incurring
Costs for Liquid Land Application for All Regulatory Options 6-13
6.1.1-8 Beef Feedlots, Heifer Operations, and Dairies Incurring
Costs for Nutrient Management Planning for All Regulatory Options 6-14
6.1.2-1 Frequency Factors Identified from Literature and
Used to Calculate Low, Medium, and High Frequency Factors for
Beef and Dairy Cost Model '. 6-16
6.1.3-1 Percentage of Beef Feedlots, Heifer Operations, Dairies, and
Veal Operations Incurring Costs to Install a Naturally Lined Pond
or Lagoon 6-18
6.1.3-2 Percentage of Category 2 Beef Feedlots, Heifer Operations, and
Dairies Incurring Costs for Transporting Excess Manure and
Waste Off Site 6-19
6.2-1 Percentage of Nitrogen-Based and Phosphorus-Based Application
Facilities 6-22
6.3-1 « Percentage of Category 1, 2, and 3 Facilities Using Nitrogen- and
Phosphorus-Based Applications 6-24
6.4-1 Illustration of Method to Calculate Frequency Factors from
Weighted Averages 6-27
xv
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LIST OF TABLES (Continued)
Page
6.4-2 Broiler Frequency Factors: Percent of High (H), Medium (M), Low (L)
Performance Facilities By Region That Already Incur Costs 6-29
6.4-3 Turkey Frequency Factors: Percent of High (H), Medium (M), Low (L)
Performance Facilities That Already Incur Costs 6-30
6.4-4 Layer Frequency Factors: Percent of High (H), Medium (M), Low (L)
Performance Facilities That Already Incur Costs 6-31
6.4-5 Swine Farrow-to-Finish Operations (Lagoon and Evaporative Lagoon)
Frequency Factors: Percent of High (H), Medium (M), Low (L)
Performance Facilities That Already Incur Costs 6-32
6.4-6 Swine Farrow-to-Finish Operations (Deep Pits) Frequency Factors:
Percent of High (H), Medium (M), Low (L) Performance Facilities
That Already Incur Costs • • • 6-33
6.4-7 Swine Grow/Finish Operations (Lagoon and Evaporative Lagoon)
Frequency Factors: Percent of High (H), Medium (M), Low (L)
Performance Facilities That Already Incur Costs 6-34
6.4-8 Swine Grow/Finish Operations (Deep Pits) Frequency Factors:
Percent of High (H), Medium (M), Low (L) Performance Facilities
That Already Incur Costs . .: 6-35
6.5-1 AFO Nutrient Management Planning Basis by Animal Sector and
Region Based on Percentage of Agricultural Soils Analyzed by Soil Test
Laboratories in 1997 That Tested High or Above for Phosphorus 6-40
6.6-1 Percentage of Category 1, 2, and 3 Operations for Layers and Turkeys ..... 6-41
6.2-1 Percentage of Facilities Incurring Ground Water Costs
Under Option 3 A/3B 6'42
6.2-2 Percentage of Beef Feedlots, Dairies, and Heifer Operations
Incurring Ground Water Costs Under Option 3C/3D 6-44
7.1.1-1 Component Costs for Option 2 That Do Not Vary by
Nutrient Application Basis Flush Dairy, Large 1, Central 7-3
7.1.1-2 Component Costs for Option 2 That Vary by
Nutrient Application Basis Flush Dairy, Large 1, Central 7-4
xvi
-------
LIST OF TABLES (Continued)
7.1.1-3
7.1.2-1
7.1.2-2
7.1.3-1
7.1.3-2
7.1.3-3
7.1.4-1
7.2-1
7.2-2
7.2-3
7.2-4 ,
7.2-5
7.2-6 i
Page
• Transportation Costs for Option 2 Flush Dairy, Large 1, Central 7-5
Percentage of Operations Assumed to Have Equivalent Technology
InPlace Flush Dairy, Large 1, Central 7.5
='. \ii-~.
Weighted Component Costs for Option 2 That Do Not Vary by
Nutrient Application Basis and Land Availability Category
Medium Performance, Flush Dairy, Large 1, Central 7.7
Weighted Component Costs for Option 2 That Vary by
Nutrient Application Basis and Land Availability Category
Medium Performance, Flush Dairy, Large 1, Central 7-8
Land Availability Category Frequency Factors
Dairies, Large 1 . .. 7.9
Weighted Farm Costs for Option 2
Medium Performance, Flush Dairy, Large 1, Central
7-11
Model Farm Costs by Category
Medium Performance, Flush Dairy, Large 1, Central 7-12
Component Costs for That Do Not Vary by Option, Facility Category, or
Manure Nutrient Application Basis
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-15
Component Costs for Facilities that Land Apply Manure On-Site
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-15
Component Costs for That Do Not Vary by Facility Based on Head Count
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-16
Component Costs for Options 1 and 2 That Vary by Facility
Based on Acreage (Category 1 and 2 only)
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-17
Component Costs That Are Unique to Category 2 Facilities Options 1 and 2
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-19
Percent Operations Assumed to Have Equivalent Technology In Place
Swine Grow-Finish Operations with Lagoons, Large 1, Mid-Atlantic
Region 7-21
xvu
-------
LIST OF TABLES (Continued)
Page
7.2-7 Adjusted Component Costs That Do Not Vary by Option, Facility
Category, or Manure Nutrient Application Basis Swine Grow-Finish with
Lagoons, Large 1, Mid-Atlantic 7-22
7.2-8 Adjusted Component Costs for Option 2 That Do Not Vary for Facilities
That Land Apply Manure On Site
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic 7-23
7.2-9 Adjusted Component Costs That Vary by Facility
Based on Head Count
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic .. 7-24
7.2-10 Adjusted Component Costs by Performance Level for Options 1
and 2 That Vary by Facility Based on Acreage (Category 1 and 2 only)
Swine Grow-Finish with Lagoons, Large ,1, Mid-Atlantic . 7-25
7.2-11 Adjusted Component Costs That are Unique to Category 2 Facilities
Options 1 and 2, Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic . . 7-26
7.2-12 Assumed Nutrient Land Application Frequency For
Total Facilities For Key Swine Regions Under Option 2 7-27
7.2-13 Final Weighted Costs for Large 1 Grow-Finish Swine Operations
With Lagoons in the Mid-Atlantic Region Under Options 1 and 2 7-29
8.2-1
Results of Cost Driver Analysis 8-4
XVlll
-------
LIST OF FIGURES
Page
1.1-1 : Animal Feeding Operation (AFO) Production Regions . . .............. . . 1-7
1.2.1^1 Beef and Heifer Model Farm Waste Management System . ............ . . 1-10
1.2.2-1 Dairy Model Farm Waste Management Systems .................. .... 1-13
1.2.3-1 Veal Model Farm Waste Management System ....................... 1-15
1.2.4-1 Swine Model Farm Waste Management System ........... ... ........ 1-17
1.2.5-1 Poultry Model Farm Waste Management System ........ ... . . ........ 1-21
2.1-1 Flow Chart of General Cost Methodology ........................... 2-2
2.1.2-1 Components of Technology Cost Modules . . : ........ ....... ....... . ; 2-6
2.2-1 Flow Chart of Swine and Poultry Cost Model ........................ 2-12
2.2.2-1 Practices Included Under Option 2A, Phosphorus-Based Management : . . . 2-19
5.1.2-1 Cross-Section of an Earthen Basin ............ . ........... ......... 5-3
5.1.2-2 Sloped Sides of Earthen Basin ............ . .......... ............. 5-8
5.2.2-1 Concrete Settling Design ....................................... 5_13
5.3.2-1 Cross-Section of Berm ............ .............. . ......... ' ..... 5.19
5.4.2-1 Cross-Section of an Anaerobic Lagoon ............................. 5-29
5.4.2-2 Volatile Solids Loading Rate (Source: USD A, 1996) ................. . 5-32
5.4.5-1 Frustrum [[[ 5.45
5.5.2-1 Cross-Section of a Storage Pond ................................. 5.55
5.8.1-1 Schematic of Center Pivot Irrigation System ......................... 5-78
5.10.2-1 Schematic of Ground- Water Monitoring Wells ... .................... 5-97
-------
LIST OF FIGURES (Continued)
Page
5.12.2-1 Windrow Composting 5-113
5.17.2-1 Scraper System 5'143
xx
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1.0
INTRODUCTION
Section 301(d) of the Clean Water Act (CWA) directs EPA to periodically review
arid revise, if necessary, effluent limitations guidelines and standards promulgated under CWA
Sections 301, 304, and 306. Concentrated animal feeding operations (CAFOs) have been
identified as a major source of nutrients impairing surface water and ground water in the United
States; therefore, EPA is revising the existing effluent guidelines for CAFOs.
For beef, dairy, heifer, veal, swine, chicken, and turkey animal feeding operations,
EPA collected data on the amount of manure and wastewater produced, the pollution control and
management practices in place, and current land-application practices at the operations. Based on
these data, EPA identified new regulatory requirements to be imposed on concentrated animal
feeding operations (CAFOs) through revision of the effluent guidelines and standards. This report
describes the methodology used to estimate engineering compliance costs (in 1997 dollars)
associated with installing and operating the various technologies and practices mat make up the
10 regulatory options considered for beef, dairy, heifer, veal, swine, chicken, and turkey
operations. The technologies described in this report were used to estimate compliance costs, but
are not necessarily mandated by the rule. In practice, a facility may choose a different waste
management system to meet the requirements of the rule.
Section 1.1 describes the regulatory options considered for CAFOs, Section 1.2
discusses the development of model farms used to determine compliance costs for each option,
Section 1.3 defines key terms used throughout this report, and Section 1.4 presents the overall
organization of the report.
1.1
Regulatory Options
EPA considered the following 10 regulatory options for CAFOs. These options
are described below:
1-1
-------
I
1 Zero discharge from a facility designed, maintained, and operated to hold
manure, litter, and other process wastewater, including direct precipitation
and runoff from a 25-year, 24-hour rainfall event. This option includes .
implementation of feedlot best management practices, including storrnwater
diversions; lagoon and pond depth markers; periodic inspections; nitrogen-
based agronomic application rates; elimination of manure application within
100 feet of any surface water, tile drain inlet, or sinkhole; mortality-
handling, nutrient management planning, and recordkeeping guidelines.
1A The same elements as Option 1, with the addition of storage capacity for
the chronic storm event (10-year, 10-day storm) above any capacity
necessary to hold manure, litter, and other process wastewater, including
direct participation and runoff from a 25-year, 24-hour rainfall event.
2 The same elements as Option 1, except nitrogen-based agronomic
application rates are replaced by phosphorus-based agronomic application
rates when dictated by site-specific conditions.
3A/3B The same elements as Option 2, plus Option 3A facility costs include an
assessment of the ground water's hydrologic link to surface water; Option
3B facility costs include ground water monitoring, concrete pads,
synthetically lined lagoons and/or synthetically lined storage ponds.
3C/3D The same elements as Option 2, plus permeability standards for lagoons
and storage ponds, which may include costs for synthetically lined lagoons
and ponds. .
4 The same elements as Option 2, plus costs for additional surface water
monitoring.
5 For swine, poultry, and veal operations only, the same elements as Option
2, but is based on zero discharge with no overflow under any
circumstances (i.e., total confinement and covered storage).
5A For beef, dairy, and heifer operations only, the same elements as Option 2,
plus implementation of a drier manure management system (i.e.,
composting).
6 For the large swine and dairy operations only, the same elements as Option
2, plus implementation of anaerobic digestion with energy recovery.
7 The same elements as Option 2, plus timing restrictions on land application
of animal waste to frozen, snow-covered, or saturated ground.
EPA also conducted several sensitivity analyses, described in Section 8.
1-2
-------
EPA selected Option 2 as BAT for all CAFOs and as New Source Performance
Standards (NSPS) for beef feedlots, dairies, and heifer operations. EPA selected Option 5 as
NSPS for swine, poultry, and veal operations or containment for 100-year storm (see the
Technical Development Document for additional information). un t^,.. • r,r
, •; To determine the 'cost of complying with each option, EPA developed model farms
that form the basis of the cost estimate for each type of operation under the regulatory options.
The waste management technologies that make up the model farms are based primarily on the
animal type and the types of waste managed. Waste management practices determine the amount
of manure waste and wastewater generated that are used to size and cost various technologies or
practices. Where differences in production practices (such as the finishing versus farrowing phases
of swine production) or waste management practices (such as under-house pits versus lagoons)
are significantly different within an animal sector, EPA developed additional model farms to better
reflect costs incurred by each type of operation. Ultimately, EPA developed more than 15,000
model farms to reflect the variability in production, waste management, farm size, cropland
availability, and regional and climatic differences. Table 1.1-1 presents the technologies and
practices that are included for each option.
'. The types of operations used to model beef, dairy, heifer, swine, chicken, turkey,
and veal facilities are summarized below:
Beef feedlots and heifer operations house cattle on drylots. The manure
that is deposited in the drylot is periodically scraped and stockpiled on site
or is transported to cropland on or off site. It is handled as a solid material.
Runoff from the feedlot operation is collected and stored in a waste storage
pond with capacity for the 25-year, 24-hour rainfall and 180 days of
storage. Runoff is treated in a sedimentation basin before going to the
storage pond.
1-3
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bComposting is includet
1-4
-------
Dairies with flush barns house the milking cows (both lactating and dry) in
freestall barns that are flushed twice'daily while the cows are being milked.
The cows are milked in separate parlors that are flushed between milkings.
Flush water and manure is collected in a central collection system and
transported to an on-site anaerobic lagoon, with capacity for the 25-year
24-hour rainfall and 180 days of storage. The wastewater is treated in a
solids separator before going to the lagoon.
Immature animals (i.e., heifers and calves) are housed on drylots. The
manure that is deposited in the drylot is periodically scraped and stockpiled
on site or is transported to cropland on or off site. It is handled as a solid
material. Runoff from the drylot is routed directly to the lagoon!
Dairies with scrape barns house the milking cows (both lactating and dry)
in freestall barns that are scraped daily. The scraped manure is stored on
site or is transported to cropland on or off site. The cows are milked in
separate parlors that are hosed down between milkings. Parlor hose water
and manure is collected in a central collection system and transported to an
on-site anaerobic lagoon with capacity for the 25-year, 24-hour rainfall
event and 180 days of storage. Wastewater is treated in a solids separator
before going to the lagoon.
Immature animals (i.e., heifers and calves) are housed on drylots. Their
manure is handled as described under flush bams above.
Veal operations house the veal calves in confinement bams that are flushed
daily. The flush water and manure is collected and stored in a central
collection system, usually a lagoon or a pit under the barn, until it is
transported to cropland on or off site. Storage lagoons are sized to hold
180 days of storage.
Farrow-to-finish swine operations house swine in total confinement barns.
Farrow-to-finish operations include all common production phases
including farrowing, nursery, and finishing (final production). Manure
from these operations is stored in a pit under the house, flushed to an on-
site anaerobic lagoon with capacity for direct precipitation from the 25-
year, 24-hour rainfall event, or flushed to an evaporative lagoon.
Grow/finish operations house swine in total confinement barns.
Grow/finish operations specialize in the finishing phase. Manure from these
operations is stored in a pit under the house, flushed to an on-site anaerobic
lagoon with capacity for direct precipitation from the 25-year, 24-hour
rainfall event, or flushed to an evaporative lagoon.
Broilers are housed in total confinement barns on the floor where
droppings are mixed with bedding such as wood shavings to form litter.
1-5
-------
Litter close to drinking water forms a dry cake that is removed between
flocks. The rest of the litter in a broiler house is removed periodically
(usually every 1 to 3 years) from the barns.
• Layers are confined in cages in high-rise housing or shallow pit flush
housing. In a high-rise house, the layer cages are suspended over a bottom
story, where the manure is deposited and stored. In shallow pit flush
housing, a single layer of cages is suspended over a shallow pit. Manure
drops directly into the pit, where it is flushed periodically to an on-site
anaerobic lagoon using recycled lagoon water.
• Turkeys, like broilers, are raised hi total confinement bams on the floor
where droppings are mixed with bedding such as wood shavings to form
litter. Litter close to drinking water forms a cake that is removed between
flocks. The rest of the litter in a broiler house is removed periodically
'(usually every 1 to 3 years) from the barns.
Each model farm is analyzed under three possible land availability scenarios,
named Category 1, Category 2, and Category 3. Operations in Category 1 have sufficient
cropland to land apply all of their manure and waste, and therefore have no transportation costs.
Operations in Category 2 have some cropland. Therefore, Category 2 operations land apply a
portion of then- manure and waste and transport the remainder off site. Operations in Category 3
have no cropland, and therefore transport all of their manure and waste off site. Note that some
operations are Category 1 when applying manure and wastewater on a nitrogen-based rate, but
may become Category 2 operations when applying manure and wastewater on a phosphorus-
based rate.
Each model farm is located in one of five geographic regions. These regions were
developed by EPA from data received from the Economic Research Service (ERS) of USDA.
ERS has developed 10 agricultural regions of the country for use in grouping economic
information. EPA originally planned to model costs using these 10 regions. However, the National
Agricultural Statistics Service (NASS) required certain ERS regions to be combined in order to
meet disclosure criteria for both economic data and census data. Therefore, the 10 ERS regions
were condensed into the five regions used in this model based on similarities in animal production
and manure handling techniques across adjacent regions. Figure 1.1-1 presents the states that are
contained within each of the. five modeled regions.
1-6
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Figure 1.1-1. Animal Feeding Operation (AFO) Production Regions
1-7
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1.2
Model Farm Descriptions
For each regulatory option, EPA estimated the costs to install, operate, and
maintain specific techniques and practices. EPA traditionally develops either facility-specific or
model facility costs. Given the amount and type of information that is available for the beef, dairy,
swine, poultry, and veal industries,.EPA has chosen a model-facility approach to estimate
compliance costs. Model facilities, or model farms, are defined by the size of the operation,
regional location, and/or waste management practices. The development of each model farm, as
well as the number of facilities by model farm, are described in more detail below. All model
farms reflect Medium of Large CAFOs.
1.2.1
Beef Feedlots and Heifer Operations
EPA developed one type of model farm to represent medium- and large-sized beef
feedlots and heifer operations in the United States. The parameters describing the beef and heifer
model farm were developed from information from USD A, data collected during site visits to beef
feedlots across the country, meetings with USDA extension agents, the National Cattlemen's Beef
Association, and the National Milk Producers Federation, and discussions with the Professional
Heifer Growers Association. A description of the various components that make up the model
farm is presented below, with the sources of the information used to develop that piece of the
model farm referenced.
Housing
The vast majority of beef feedlots and heifer operations in the United States house
the cattle on drylots (USDA APHIS, 1995). Some smaller operations use confinement barns at
beef feedlots. However, since the majority of operations, including most new ones, use open lots,
EPA used drylots as the housing for the beef model farm. Some operations raise the heifers on
pasture, but because this regulation addresses only confined operations, the heifer model farm
accounts only for animals housed on drylots. The size of the drylot is calculated using animal
space requirements suggested by Midwest Plan Service (MWPS, 1995).
1-8
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••'•- Waste Management System
Based on site visits, the drylot is the main area where waste is produced at beef
feedlots and heifer operations. Waste from the drylot includes solid manure, which has dried on
the drylot, and runoff, which is produced from precipitation that falls on the drylot and open feed
areas.
Most beef operations in the United States divert runoff from the drylot to a storage
pond (USDA APHIS, 1995a). Heifer operations typically operate like beef feedlots (Cady, R,
2000). As such, EPA assumed that runoff from the drylot is channeled to a storage pond at both
beef and heifer operations. Some operations use a solids separator (typically an earthen basin) to
remove solids from the waste stream prior to the runoff entering the pond. Solid waste from the
drylot is often mounded on the drylot to provide topography for the cattle and is later moved
from the drylot for transportation off site or land application on site (USDA APHIS, 1995a).
^ .....'._.
The beef and heifer model farm was developed following these typical
characteristics of beef feedlots and heifer operations. Figure 1.2:1-1 presents the waste
management system used as part of the beef and heifer model farm.
Region
; Data from site visits indicate that beef feedlots in varying regions of the country
have different characteristics. These differences are primarily related to climate. For example, a
beef feedlot in the Midwest region receives a greater amount of rainfall annually than a beef
feedlot in the Central region; therefore, the Midwest feedlot produces a greater volume of runoff
to be contained and managed. Because operating characteristics may change between regions to
accommodate these climatological differences, beef feedlots are modeled in five diverse regions of
the United States: Central, Mid-Atlantic, Midwest, Pacific, and South, as described in Section 1.1.
Data from USDA indicate that heifer operations are located in similar areas as beef feedlots and
would have similar characteristics as the beef feedlots.
1-9
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Solids (98.5%)
Figure 1.2.1-1. Beef and Heifer Model Farm Waste
Management System
1.2.2
Dairies
EPA developed two model farms to represent medium- and large-sized dairies in
the United States: a flush dairy and a hose/scrape dairy. These types of farms were identified as
the predominant type of dairy in the United States based on data collected from site visits and
NAHMS. EPA developed the parameters describing the dairy model farms are developed from
information from USD A, 1997 Agricultural Census data, data collected during site visits to dairy
farms across the country, meetings with USDA extension agents, and meetings with the National
Milk Producers Federation and Western United Dairymen. A description of the various
1-10
-------
components that make up the model farms is presented below, with the sources of the information
used tb develop each piece of the model farm.
» •• ..• Housing
To determine the type of housing used at the model farm, the type of animals on
the farm were considered. In addition to the mature dairy herd (including lactating, dry, and
close-up cows), there are often other animals on site at the dairy, including calves and heifers.
The number of immature animals (i.e., calves and heifers) at the dairy is proportional to the
number of mature cows in the herd, but further depends on the farm's management. For example,
the dairy may house virtually no immature .animals on site and obtain their replacement heifers
from off-site operations, or the dairy could have close to a 1:1 ratio of immature animals to
mature animals. Site visits suggest the trend that the largest dairy managers want to focus on milk
production only, and prefer not to keep heifers on site.
Typically, according to Census of Agriculture data, for dairies greater than 200
milking cows, the number of calves and heifers on site equals approximately 60 percent of the
mature dairy (milking) cows (USDA, 1997). EPA assumes that there are an equal number of
calves and heifers on site (30 percent each) at the dairy model farms. Based on this information,
the number of calves-on site is estimated to be 30 percent of the number of mature cows on site,
as are the number of heifers on site, for the dairy model farm. The percentage of bulls is typically
small (USDA, 1997),. as most dairies do not keep them on site. For this reason, EPA assumed
that their impact on the model farm waste management system is insignificant, and did not
consider bulls in the dairy model farm.
The most common types of housing for mature cows include freestall barns, tie
stalls/stanchions, pasture, drylots, and combinations of these (Stall, CE., et. al. eds. 1998).
Based on site visits, most medium- to large-sized dairies (>200 mature dairy cows) house their
mature dairy cows in freestall bams; therefore, it is assumed that mature dairy cows are housed in
freestall barns for the dairy model.
1-11
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The most common types of calf and heifer housing are drylots, multiple animal
pens, and pasture (USDA APHIS, 1996a). Based on site visits, most medium- to large-sized
facilities use drylots to house their heifers and calves; therefore, it is assumed .that calves are
housed in hutches on drylots and heifers are housed in groups on drylots at dairies described in
the model. EPA calculated the size of the drylot for the model farm using animal space
requirements suggested by Midwest Plan Service (MWPS, 1995).
Waste Management Systems
Waste is generated in two main areas at dairies: the milking parlor and the 'housing
areas. Waste from the milking parlor includes manure and wash water from cleaning the
equipment and the parlor after each milking. Waste from the confinement bams includes bedding
and manure for all bams, and wash water if the barns are flushed for cleaning. Waste generated
from the drylots includes manure and runoff from any precipitation that falls on the drylot.
Based on site visits, most dairies transport their wastewater from the parlor and
flush barns to a lagoon for storage and treatment. Some dairies use a solids separator (either
gravity or mechanical) to remove larger solids prior to the wastewater entering the lagoon. Solids
are removed from the separator frequently to prevent buildup in the separator, and they are
stockpiled on site. Solid waste scraped from a bam is typically stacked on the feedlot for storage
for later use or transport. Solid waste on the drylot is often mounded on the drylot for the cows
and is later moved for transport or land application. Wastewater in the lagoon is held in storage
for later use, typically as fertilizer on cropland either on or off site. Figure 1.2.2-1 presents the
waste management systems used for model dairy farm.
The amount of waste generated at a dairy depends on how the operation cleans the
bam and parlor on a daily basis. Some, dairies clean the parlor and barns by flushing the waste (a
flush dairy); othereuse less water, hosing down the parlor and scraping the manure from the bams
(a hose/scrape dairy). EPA estimated the percentage of total dairies that operate as a flush dairy
or a hose/scrape dairy using USDA data (USDA APHIS, 1996a) and described in Section 4.3.2 of
1-12
-------
this report. Both flush and hose/scrape dairy systems are modeled separately as two model
facilities.
Flush Dairy
Solids
Figure 1.2.2-1. Dairy Model Farm Waste Management Systems
1-13
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Region
Data from site visits indicate that dairies in varying regions of the country have
different characteristics. These differences are primarily related to climate. For example, a dairy
in the Pacific region receives a greater amount of rainfall annually than a dairy in the Central
region; therefore, the Pacific dairy produces a higher amount of runoff to be contained and
managed. Because operating characteristics may change between regions, dairies are modeled in
five distinct regions of the United States: Central, Mid-Atlantic, Midwest, Pacific, and South, as
described in Section 1.1.
1.2.3
•Veal Operations
EPA developed one model farm to represent medium- and large-sized veal
operations in the United States. The parameters describing the veal model farm are developed
from information collected during site visits to veal operations in Indiana and discussions with the
American Veal Association. A description of the various components that make up the model
farm is presented below, with the sources of the information used to develop that piece of the
model farm referenced. ;
Housing
Veal calves are generally grouped by age in environmentally controlled buildings.
The majority of veal operations in the United States utilize individual stalls or pens with slotted
floors, which allow for efficient removal of waste (Wilson, 1995). Because this type of housing is
the predominant type of housing used in the veal-producing industry, individual stalls in an
environmentally controlled building is designated as the housing for the veal model farm.
1-14
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Waste Management Systems
Based on site visits, the only significant source of waste at veal operations is from
the veal confinement areas. Veal feces are very fluid; therefore, manure is typically handled in a
liquid waste management system. Manure and waste that fall through the slotted floor are flushed
regularly out of the barn. Flushing typically occurs twice daily. Most veal operations have a
lagoon to receive and treat their wastewater from flushing, although some operations have a
holding pit system in which the manure drops directly into the pit. The pit provides storage until
the material can be land applied or transported off site. Wastewater in the lagoon is held in
storage for later use as fertilizer off site.
(
EPA developed the veal model farm used in the cost model from these general
characteristics. The animals are totally confined; therefore, the only source of wastewater is from
flushing the manure and waste from the barns. Direct precipitation is also collected on the lagoon
surface, if the lagoon is uncovered. Figure 1.2.3-1 presents a diagram of the veal model farm
waste management system.
Solids
Freestall
Barn (Flush)
>.
1
Solids
Separation
present)
•*i»
^*
T.flgppn
^~
v
End Use
Figure 1.2.3-1. Veal Model Farm Waste Management System
Region
The American Veal Association indicates that veal producers are located
predominantly in the Midwest and Central regions (Crouch, A., 1999); therefore, only these two
regions are modeled as part of the veal model farm.
1-15
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1.2.4
Swine Operations
EPA developed the parameters describing the model swine farms using information
from the USDA NASS, site visits to swine farms across the country, discussions with the National
Pork Producers Council, and the USDA Natural Resources Conservation Service (NRCS). A
description of the various components that make up the model farm is presented in the following
discussion, and the sources of the information used to develop each piece of the model farm are
noted.
Housing
Swine are typically housed in total confinement barns, and less commonly in. other
housing configurations such as open buildings with or without outside access and pastures
(USDA APHIS, 1995b). On many farms, small numbers of pigs (fewer than the number covered
by this regulation) are raised outdoors; however, the trend in the industry is toward larger
confinement farms at which pigs are raised indoors (NCSU, 1998). For these reasons, the model
swine farm is assumed to house its animals in total confinement barns.
Waste Management Systems
The characteristics of waste produced at an operation depends on the type of
animals that are present. In farrow-to-finish operations, the pigs are born and raised at the same
facility. Therefore, the manure at a farrow-to-finish farm has the characteristics of mixed excreta
from varying ages. In grow-finish facilities, young pigs are first born and cared for at a nursery,
and then brought onto the finishing farm. Therefore, the manure at a grow/finish farm has
characteristics of pigs older than 7 weeks. These are the two predominant types of swine
operations in the United States for the size classes that would be covered under the final mile.
The Technical Development Document contains additional information on herd and waste
characteristics.
1-16
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Swine houses with greater than 750 head typically store their wastes in pits under
the house or flush the wastes to outside lagoons. Slatted floors or flush alleys are used to
separate manure and wastes from the animal. It is common to allow manure to collect hi a pit and
wash the pit one to six times per day with water to move the waste to a lagoon. The waste is
stored in the lagoon until it is applied to land or transported off site. Storing the waste in an
anaerobic lagoon provides sonie treatment during storage, conditioning the wastewater for later
land application, and reducing odors (NCSU, 1998). EPA developed model farms for farrow-to-
finish and grow/finish operations in the Mid-Atlantic and Midwest regions that are assumed to use
pits or flush alleys and anaerobic lagoon storage.
In the Midwest, a deep pit storage system is more common. Deep pit systems start
with several inches of water in the pit, and the manure is collected and stored under the house
until it is pumped out for field application, typically twice a year. This system uses less water,
creating a manure slurry that has higher nutrient concentrations than the flush system described
earlier. A survey of swine operations in 2000 shows that both lagoons and deep pits are
commonly used for waste storage in the Midwest region (USDA APHIS, 2002). For purposes of
developing the cost models, EPA estimated, from the USDA APHIS (2002) data, the percentage
of farrow-to-finish and grow/finish operations in the Mid-Atlantic and Midwest regions that use
pit storage. EPA developed model farms for farrow-to-finish and grow/finish operations in the
Mid-Atlantic and Midwest regions that are assumed to use pit storage pumped twice per year.
Although not present in the statistics that were available to the EPA at the time of
this analysis, EPA recognizes the increasing number of large swine operations in the Central
region. Many of these larger operations in the Central region use evaporative lagoons instead of
traditional anaerobic lagoons found in the Mid-Atlantic and Midwest. Thus, EPA developed
model farms for large facilities in the Central region and assumed evaporative lagoons are used for
waste storage.
EPA's swine model farm's under Option 5 assume that all lagoons are covered
with a synthetic cover. Facilities that use deep pit storage are not assumed to need any additional
practices to comply with Option 5.
1-17
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Figure 1.2.4-1 .presents'1 these waste management systems used for the model swine
farms in this cost model.
1 :!lvl,l
-------
were modeled in both regionsT targe swine operations that use evaporative lagoons for waste
storage were modeled in the Central region. 'Operations located in other regions were split among
the modeled regions to folly account for operations in a given size class. Allocating operations
from one region to another was necessary since the census data could not be obtained for all
desired regions and size groups (USDA NASS, 1999). Table 1.2.4-1 presents a summary of the
swine model farms developed by EPA.
Table 1.2.4-1
Model Swine Farms by Farm Type, Size, Region, and Waste Storage System
Farm Type
Farrow-to-
Finish
Grow/Finish
Size Group '
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
•Region
Central
NM
NM
NM
Evap Lagoon
Evap Lagoon
.: NM-,..
NM
NM
Evap Lagoon
Evap Lagoon
Mid-Atlantic
L&P
L&P
L&P
L&P
L&P
L & P
L&P
L&P
L&P
L&P
Midwest ,
L&P
L&P
L&P
L&P
L&P
L&P
L&P
L&P
L&P
L&P
Pacific
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
South
NM
NM
NM
NM
NM
NM
NM
NM
NM
»_* —fy -
P = under house pit storage
Evap Lagoon = evaporative lagoon storage
NM = Not modeled in this region.
1.2.5
Poultry Operations
EPA developed four model farms to represent poultry operations in the United
States. The model farms are broiler, turkey, dry layer, and wet layer operations. EPA developed
the parameters describing the model poultry farms using information from NASS, site visits to
poultry farms across the country, and the USDA NRCS. A description of the various components
1-19
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of each model farm is presented in the following discussion, and the sources of the information
used to develop each piece of the model farm are noted.
Housing
Broilers and turkeys are typically housed in long barns (approximately 40 feet wide
and 400 to 500 feet long; NCSU, 1998) and are grown on the floor of the house. The floor of the
bam is covered with a layer of bedding, such as wood shavings, and the broilers or turkeys
deposit manure directly onto the bedding. Approximately 4 inches of bedding are initially added
to the houses and top dressed with about 1 inch of new bedding between flocks.
Layers are typically confined in cages in high-rise housing or shallow pit flush
housing. In a high-rise house, the layer cages are suspended over a bottom story, where the
manure is deposited and stored. EPA used this configuration to model housing for dry layer
model farms. In shallow pit flush housing, a single layer of cages is suspended over a shallow pit.
Manure drops directly into the pit, where it is flushed out periodically using recycled lagoon
water. EPA used this configuration to model housing for wet layer model farms.
These poultry housing systems are considered typical systems in the poultry
industry (NCSU, 1998). Therefore, the cost model uses these farm housing systems in the model
farms.
Waste Management Systems
Manure from broiler and turkey operations accumulate on the floor where it is
mixed with bedding, forming litter. Litter close to drinking water forms a cake that is removed
between flocks. The rest of the litter hi a house is removed periodically (6 months to 2 years)
from the barns, and then transported off site or applied to land. Typically, broiler and turkey
operations are completely dry waste management systems (NCSU, 1998). Therefore, EPA used
this waste management configuration in modeling both broiler and turkey model farms.
1-20
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reflects the South and Mid-Atlantic regions, and the model layer farm reflects the Midwest and
South regions. State-level data from the 1997 Census of Agriculture indicate that states in the
Midwest and Mid-Atlantic regions of the United States account for over 70 percent of all turkey
turkeys produced. For this reason, model turkey farms are located in-the Mid-Atlantic and '
Midwest regions (USDA NASS, 1999). Table 1.2.5-1 presents the number of facilities modeled
for the poultry model farms.
Table 1.2.5-1
Model Poultry Farms by Farm Type, Size, and Region
Farm .Type-.;
Broilers
Dry Layers
Wet Layers
Turkeys
Size Group
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
- Region
Central
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
Mid-Atlantic
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
NM
NM
Y
Y
Y
Y
Midwest
NM
NM
NM
NM
NM
Y
Y
Y
Y
Y
NM
NM
Y
Y
Y
Y
Pacific
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM :
NM
NM
NM
NM
NM
NM
, South
Y
Y
Y
Y
Y
NM
NM
NM
NM
NM
Y
Y
NM
NM
NM
NM
Y.= model larni was developed for this region.
NM = model farm was not developed for this region.
1-22
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Layer operations may operate as a wet or a dry system. Approximately 12 percent
of layer houses use a liquid flush system, in which waste is removed from the house and stored in
a lagoon (USDA APHIS, 2000). Operations that use this type of waste management system are
referred to as wet layers. The remaining layer operations typically operate as dry systems, with
manure stored in the house for up to a year. A scraper is used to remove waste from the
collection pit or cage area (NCSU, 1998). Operations that use this type of waste management
system are referred to as dry layers. The lagoon wastewater and dry manure are stored until they
are applied to land or transported off site: Figure .1.2.5-1 presents the waste management systems
for poultry. ':'
Broiler
House
Broiler House
with Bedding
i
t
Storage
i
End
f
Use
r'
Turkey
House ~
Turkey House
with Bedding
i
p
Storage
?
End
r
Use
Caged Uatyer
Shallow Pit
Flush House
Shallow Pit
Flush House
T
r
Anaerobic
Lagoon
i
End
r
Use
<
^aged liajier
High-rise
House
High-rise '
House
1
r
End Use
Figure 1.2.5-1 Poultry Model Farm Waste Management System
Region
Data from site visits and North Carolina State University's draft~ Swine and Poultry
Industry Characterization indicate that the predominant type of waste management system at
poultry operations varies from region to region (NCSU, 1998). Most of the broiler operations in
the United States are located in the South and Mid-Atlantic regions, while most of the egg-laying
operations are located in the Midwest and South regions. Therefore, the model broiler farm
1-21
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1.3
Key Terms
This subsection discusses the key terms used in the cost model report, including
size groups, frequency factors (technology factors that vary by performance level, technology
factors that do not vary by performance level, land availability factors, nutrient management
factors), and manure and wastes.
1.3.1
Size Groups.
EPA developed and analyzed up to five size groups for each animal type. The size
groups include one to two size groups for "Large" farms and up to three size groups for
"Medium" farms. Table 1.3-1 presents the size groups for each animal type.
Table 1.3-1
Size Classes for Model Farms
Animal Type
Beef
Heifer
Dairy (Mature
Dairy Cows)
Veal
Swine
Dry Layers
Wet Layers
Broilers
Turkeys
Medium 1
300-499
300-499
200-349
300-499
750-1,249
25,000-49,999
N/A
37,750-49,999
16,500-27,499
Medium 2
500-749
500-749
350-524
500-749
1,250-1,874
50,000-74,999
N/A
50,000-74,999
27,500-41,249
Medium3
750-999
750-999
525-699
>750
1,875-2,499
75,000-81,999
9,000-29,999
75,000-124,999
41,250-54,999
Large 1
1,000-7,999
2:1,000
2:700
N/A
2,500-4,999
82,000-599,999
>30,000
125,000-179,999
2:55,000
' Large 2
;>8,000
N/A
N/A
N/A
;>5,000
>600,000
N/A
2:180,000
N/A
N/A - Not applicable.
In this report, references to the model farm size classes will be capitalized. For
example, Large would refer to all operations that fall into the Large 1 or Large 2 model farm size
classes. When the terms are not capitalized (i.e., "large"), they are used in a general way.
1-23
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1.3.2
Frequency Factors
EPA developed frequency factors to reflect the baseline industry conditions
(industry conditions prior to implementation of the regulation), m the cost model, four types of
frequency factors are employed: technology frequency factors that do not vary by performance
level, technology frequency factors that dp vary by performance level, land availability frequency
factors, and nutrient management frequency factors.
The model-farm approach used in the cost model provides the average cost a farm
is projected to incur under the proposed regulatory options. EPA recognizes that this approach
might underestimate or overestimate the projected costs for farms that are on the extreme ends of
applicability. For example, some farms might already meet the proposed regulatory requirements;
therefore, those farm costs would be zero.jMternatively, some farms might meet very few of the
proposed regulatory requirements; therefore, those operations would incur costs much higher
than the "average" model farm costs. Therefore, EPA used frequency factors that vary according
to the requirements of the model farm. EPA assumed 25% of farms will have high requirements,
25% will have low requirements, and 50% will have moderate requirements. Frequency factors
were estimated according to these assumptions.
Technology Factors That Vary by Performance Level
Technology frequency factors reflect the percentage of operations that have a
particular operation, technique, or practice in place at baseline. In most cases, the frequency
factors have a performance level (i.e., high, medium, or low performance) as estimated by USDA.
Frequency factors that vary by performance level were developed for the following practices or
technologies:
• Feeding strategies;
• Solids separation using earthen and concrete settling basins;
• Runoff controls (e.g., berms);
1-24
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Liquid land application (e.g,. center pivot irrigation); and
Nutrient management planning (i.e., setbacks, lagoon markers, soil
sampling, manure sampling, recordkeeping, document preparation).
Technology Factors That Do Not Vary by Performance Level
Two of the technology components of the cost model are not based on USDA's
performance-based data. The frequency factors for naturally-lined ponds and lagoons and
transportation are based on several different data sources as discussed in Section 6.1.3.
Land Availability Factors
Operations fall into three categories with respect to the amount of on-site cropland
available for manure application. Using USDA data, EPA calculated the percentage of facilities i
each of these categories:
in
Category 1 operations have sufficient land to land-apply all of then-
generated manure and wastewater at appropriate agronomic rates. No
manure is transported off site.
Category 2 operations do not have sufficient land to land-apply all of then-
generated manure and wastewater at appropriate agronomic rates. The
excess manure after agronomic application is transported off site.
Category 3 operations do not have any available land for manure
application. All generated manure and wastewater is transported off site.
Nutrient Management Factors
In the proposed regulation, the land application of manure is governed by the rate
determined by the Director and for the purposes of this analysis is assumed to be agronomically
limited by either nitrogen or .phosphorus. This assumption ensures that EPA has calculated the
highest costs of this regulation. Several cost modules compute component costs separately for
1-25
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both nitrogen- and phosphorus-based application and are adjusted based on frequency factors that
indicate the use of the component in the industry. For Options 1 and 1A, all operations are costed
for nitrogen-based application, and for Option 2A, all operations are costed for phosphorus-based
application. However, under the remaining options, EPA used soil tests and USD A data to
determine the percent of facilities in each state that would require nitrogen-based versus
phosphorus-based application rates. This ranges from 12% to 66% across animal type and region,
but roughly 50% of all facilities would need to apply at a phosphorus rate.
1.3.3
Manure and Waste
In the cost model report, manure refers to excreted manure with no added process
water or rain water. Waste and wastewater may refer to the combination .of manure and
contaminated runoff, process water, and cleaning water. This does not necessarily reflect the
official language of the preamble of this regulation.
1.4
Organization of Report
The following information is discussed in detail in this report:
* Section 2.0 presents the structure of the cost model;
• Section 3.0 discusses the data sources used to generate compliance costs;
• Section 4.0 discusses the cost model inputs;
• Section 5.0 discusses the methodology .used to calculate costs;
• Section 6.0 discusses the frequency factors used in the report;
• Section 7.0 provides examples of total model farm costs calculated for beef
and dairy and swine and poultry operations as well as weighted model farm
costs for each animal sector under the selected BAT and NSPS options;
• Section 8.0 discusses sensitivity and side analyses conducted on EPA's
model farms; and
1-26
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Appendices A through D present cost results.
1.5
References
Cady, R, 2000. Telephone conversation with Dr. Roger Cady, Monsanto Company and Founder
of the Professional Dairy Heifer Growers Association. February 18, 2000.
Crouch, A., 1999. Telephone conversation with Alexa Crouch., American Veal Association.
October 14, 1999.
MWPS, 1995. Midwest Plan Service. Beef Housing and Equipment Handbook. Fourth Edition,
MWPS-6. Iowa State University. Ames, Iowa. November 1995.
NCSU, 1998. Draft of Swine and Poultry Industry Characterization, Waste Management
Practices and Modeled Detailed Analysis'of Predominantly Used Systems. September 30,
1998.
Stall, C.E., et..al. eds. 1998. Animal Care Series: Dairy Care Practices. 2nd ed, Dairy
Workgroup. University of California Cooperative Extension. June.1998.
USDA, 1997. Census of Agriculture, 1997.
USDA APHIS, 1995a. National Animal Health Monitoring System, Part I: Feedlot Management
Practices. 1995a
USDA APHIS, 1995b. National Animal Health Monitoring System: Swine '95. Parti.
Reference of 1995 Swine Management Practices.
%
USDA APHIS, 1996a. National Animal Health Monitoring System, Part III: Reference of 1996
Dairy Health and Health.
USDA APHIS, 1996b. National Animal Health Monitoring System (NAHMS), Part 1: Reference
of 1996 Dairy Management Practices.
USDA APHIS, 2000. Data summaries of NAHMS Layer '99, prepared at request of EPA.
National Animal Health Monitoring System. Washington, DC.
USDA APHIS, 2002. Queries run by Centers for Epidemiology and Animal Health prepared by
Eric Bush; March 22, 2002; 2 pages.
USDA NASS, 1999. Queries run by NASS for USEPA on the 1997 Census of Agriculture data.
U.S. Department of Agriculture, National Agricultural Statistics Service, Washington,
DC.
1-27
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Wilson, L.L., C.L. Stull, and T.L. Terosky, 1995. Scientific Advancements and Legislation
Addressing Veal Calves in North America. In: Veal Perspectives to the Year 2000,
Proceedings of an International Symposium. LeMans, France. September 12 and 13,
1995.
1-28
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2.0
COST MODEL STRUCTURE
EPA created two separate models to estimate compliance costs associated with
regulatory options for CAFOs: one model to generate beef, dairy, heifer, and veal costs, and
another model to generate swine, broiler, turkey, and layer costs. The following subsections
describe the structure of each of these models.
2.1
Beef and Dairy Cost Model
To generate industry compliance cost estimates for beef feedlots, dairies, and
heifer and veal operations, EPA developed a computer-based cost model made up of several
individual cost modules. The cost model is executed on a personal computer and consists of a
collection of programs written in Visual Basic® and data tables created in Microsoft® Access 97.
Figure 2.1-1 presents a flow chart of the general cost model methodology. The cost model
consists of several components, which can be grouped into five major categories:
Input data;
Technology cost modules;
Frequency factors (including farm-weighting factors);
Cost test; and
Model farm costs.
The beef and dairy cost model calculates costs for the following groups of model
farms, shown in Table 2.1-1.
Model outputs are presented in Appendices A through D of this report. Each
technology cost module calculates a specific piece of operational data (e.g., runoff) or develops a
component cost for a specific waste management system component (e.g., an anaerobic lagoon)
based on model farm characteristics. Frequency factors are then applied to the component costs
to weight the costs by the estimated percentage of operations that already have the component in
place. Some component-level frequency factors are performance based, and different factors are
used to estimate costs for a low-performing, medium-performing, and high-performing farm.
2-1
-------
I
Farm-Weighting
Factors
Technology
Cost Modules
Component Costs
Weighted
Component Costs
Weighted Farm
Costs
Model Farm Costs
Figure 2.1-1. Flow Chart of General Cost
Methodology
2-2
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Using these factors, cost estimates for a low-performing farm will include the majority of possible
costs, and estimates for a high-performing farm will include less of the possible costs.
Farm-weighting factors are then applied to certain weighted component costs to
further weight these costs by the percentage of operations that operate in different ways (e.g.,
flush versus hose dairies, or nutrient basis for land application). These weighted farm costs are
then summed for each regulatory option and model farm. Finally, a transportation cost test
evaluates several methods of transporting waste off site, identifies the least expensive scenario,
and outputs final costs for each model farm, and option. All costs are in 1997 dollars. The
remainder of this section describes each of these components.
2.1.1
Input Data to Cost Model
Input data to the cost model include information on the model;farms, runoff,
wastewater generation, and manure generation, as described below:
• Model farm definitions - Animal type, EPA regulatory option, farm type,
size class, average number of head, region, performance level, and number
of operations that are represented by the model farm;
• Wastewater generation - Volume of milking parlor wastewater and bam
wastewater generated;
• Manure generation - Amount and composition of manure generated at the
operation; and
• Runoff generation - Precipitation data (including average rainfall,
evaporation, and 25-year, 24-hour rainfall amounts) by model farm type
and region.
All of these data are used as inputs for cost calculations. Section 4.0 discusses
inputs to the cost model in greater detail.
2-4
-------
2.1.2
Technology Calculations
Each technology cost module calculates direct capital and annual costs for
installing and implementing a particular technology or practice. In some cases, the modules
calculate initial fixed costs that are not able to be amortized and operating and maintenance
(O&M) costs that only occur every 3 or 5 years. The cost model refers to these periodic O&M
costs as a "3-year recurring cost" or a "5-year recurring cost." ;
For each regulatory option, the cost, model combines a series of modules. Table
2.1.2-1 presents the waste management technology components for dairies, beef feedlots, and
heifer and veal operations that make up the basis for each regulatory option. Each module uses
the input data tables to generate costs to implement the technologies under each regulatory
option. Figure 2.1.2-1 presents the components of the technology cost modules, and Section 5.0
discusses each cost module in detail. The cost model uses Microsoft® Access 97 queries to create
a module-specific input page that selects only the input required to run the specific waste
management component of interest. No costs are calculated for components that are not included
in the option.
Table 2.1.2-1
Waste Management Technologies for Beef Feedlots, Dairies, and
Heifer and Veal Operations
Technology or Practice
Solids Separation
Anaerobic Treatment
Liquids Storage
Runoff Controls
On-Site Land
Application
Technology Cost Module
Concrete Basin
Earthen Basin
Naturally Lined Lagoon
Naturally Lined Pond
Berms
Nutrient Management Planning
Nutrient-Based Application
On-Site Irrigation
Off-Site Transportation
Animal Type. ;
Dairy :
/
^
S
S
S
/
s
Beef & Heifer
/
/
S
S
S
S
s
Veal
S
S
/
^
^
s
2-5
-------
I
S
T3
O
«i
O
u
o
S
o
601
ir
•£
I
2-6
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system to meet the requirements of the rule, which may vary in cost from these estimated costs.
Section 6.0 discusses the frequency factors used in the cost model.
Weighted Farm Costs
Some weighted component costs vary depending on the type of manure application
basis (nitrogen or phosphorus). To account for these differences, the cost model further weights
the weighted component costs, as necessary.
The farm-weighting factor adjusts the weighted component costs for the type of
nutrient-based application used. Note, this only applies to land application component costs that
are affected by the number of available acres. As discussed in Section 6.2, the cost model
estimates the number of operations that require nitrogen-based application and the number of
operations that require phosphorus-based application. In fact, most operations will have some
fields limited to nitrogen and some limited to phosphorus. The exact distribution will vary for
each individual operation. This approach assumes each farm will incur costs based on both
nitrogen and phosphorus, and calculates a weighted cost. To calculate costs weighted by
application method, the component costs must be proportioned between the number of nitrogen-
based operations and phosphorus-based operations. The following equation calculates the
weighted farm cost for each type operation that conducts on-site land application.
where:
' NFacs
NCost
PFacs
PCost
Weighted Cost = [(NFacs x NCost) + (PFacs x PCost)]
[NFacs + PFacs]
Number of operations that apply on nitrogen basis
Weighted unit component cost, nitrogen-based application
Number of operations that apply on phosphorus basis
Weighted unit component cost, phosphorus-based
application.
The weighted farm costs are then used in a "cost test," described in Section 5.0, to
select the least costly option to transport excess manure off site. There are four transportation
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options considered: hiring a contractor to haul manure; purchasing trucks to haul manure;
composting to reduce the volume of waste before hiring a contract hauler; and composting before
using purchased trucks. The cost model sums and annualizes the weighted farm costs for each of
the transportation scenarios, and selects the least costly scenario.
The cost estimates generated contain the following types of costs:
• Capital costs - Costs for facility upgrades (e.g., construction projects).
• Fixed costs - One-time costs for items that cannot be amortized (e.g.,
training). • • ' . . •- .••••>•
• Annual operating and maintenance (O&M) costs - Annually recurring
costs, which may be positive or negative. A positive O&M cost indicates
an annual cost to operate, and a negative O&M cost indicates a benefit to
operate, due to cost offsets.
• Three-year recurring O&M costs - Operating and maintenance costs that
only occur once every three years.
• Five-year recurring permit costs - Application fees and reporting costs
occur once every five years.
• Annual fertilizer costs - Costs for additional commercial nitrogen fertilizer
needed to supplement the nutrients available from manure application.
These costs provide the basis for evaluating the total annualized costs of each
regulatory option. Section 7.0 presents these model farm cost outputs.
2.2
Swine and Poultry Cost Model
EPA developed a computer-based cost model to generate industry compliance cost
estimates for swine and poultry operations. The cost model is executed on a personal computer
and consists of a main program and subroutines written in Digital Fortran 90, Version 6, and data
tables created in Microsoft® Excel and text format.
2-10
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Each module generates an intermediate output page, containing the capital, fixed,
annual, and recurring costs associated with that waste management system component. The
output page also includes data that may be used as input to subsequent modules..
2.1.3
Frequency Factors
EPA determined the current frequency of existing waste management practices at
beef feedlots, dairies, and heifer and veal operations to estimate the portion of the operations that
would incur costs to comply with the final regulation. The frequency information is used to
estimate compliance costs-for specific model farms. These specific technologies are not required
to meet the requirements of the regulation. Rather, they are simply for the basis of estimating
costs for cpmpliance with the regulation. The resulting weighted farm costs can be multiplied by
the number of facilities represented by each model to estimate industry-wide costs.
e
Currently, no publicly available information is available that can be used with a
high degree of confidence to determine what each frequency factor should be for each size class
within a given region. EPA, therefore, estimated frequency factors based on the sources below.
Each source was considered along with its limitations; Section 6.0 discusses in detail the
frequency factors used to develop compliance costs for each regulatory option.
USDA/Natural Resources Conservation Service (NRCS) - EPA used the
data currently available from NRCS to determine the distribution of beef
feedlots and dairies across the regions by size class, production category,
and performance level.
EPA site visit information - EPA used this information to assess general
practices of beef feedlots, dairies, and heifer and veal operations and how
they vary between regions and size classes.
Observations from industry experts - EPA contacted experts on beef and
dairy animal feeding operations to provide insight into operations and
practices, especially where data are limited or not publicly available.
USDA/Animal Plant and Health Inspection Service (APHIS)/National
Animal Health Monitoring System (NAHMS) - This source provides
information on dairy practices, facility size, and waste system components
2-7
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sorted by= size class and region. These data have limited use due to the
small number of respondents in the size classes of interest.
State Compendium: Programs and Regulatory Activities Related to
AFOs - EPA used this summary of state regulatory programs to estimate
frequency factors based on current waste-handling requirements that
already apply to beef feedlots and dairies in various states and in specific
size classes as related to off-site transportation and nitrogen-based land
application.
2.1.4
Calculation of Weighted Costs
t ,;L,
' The cost model generates weighted technology costs and weighted farm costs
from the waste management system component costs calculated within each module.
•' , ' - • • - .. > -•< ; • ," • '".. ~~t'\-'*~i*. •. 'i
Methodologies used to develop both of these costs are described below.
Weighted Technology Costs
.: ',• > ,% *-.. '••.••• •' • ' ," v'-:. •
"To ensure that' only operations that do not have the technology are costed, the cost
model weights the technology component costs to reflect the percentage of operations that
akeady have some components in place. For some technologies (e.g., settling basins), there are
three different frequency factors that represent facilities that have low, medium, and high
requirements reflecting the performance level of the farm. The cost model uses the following
equation to weight the component costs: . .
where:
Frequency Factor
Costcomponent x (1 - Frequency Factor) - ; ;
Weighted component cost
Component cost
Percentage of operations that have the component in
place.
This weighted component cost reflects the conservative assumptions made in this cost model for
compliance with the regulation. In practice, a facility may choose a different waste management
2-8
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The components of the cost model can be grouped into six major categories as
illustrated in Figure 2.2-1:
Model farm input data;
Preprocessor subroutines (get farm counts, manure characteristics, etc!);
Basic calculations (manure production, nutrient needs, etc.);
Other input data (technology performance and costs, frequency factors
etc.);
Cost subroutines for practices; and
Model farm costs (outputs).
The core of the cost model is the "Main" program. Data files with model feedlot
information, constants associated with manure characteristics and cropping systems, frequency
factors, number of farms represented by each model, technology costs, and various other variables
essential to the cost modeling effort are input into the main program and its subroutines. The
program then calculates practice-specific and total costs for each model farm. The total national
cost of the proposed regulation is estimated by multiplying model farm costs by the number of
farms represented by each particular model. The cost model creates both formatted and
unformatted outputs.
The model's subroutines read into the Main program the basic information
regarding model farms (e.g., animal type, operation type) and the various constants used in a wide
range of Main program calculations (e.g., nutrient management training costs, regional nitrogen
and phosphorus uptake values, frequency factors), and they perform the more complex
calculations (e.g., berm size, lagoon size, lagoon cover size) and analyses (e.g., selecting the least-
cost alternative for each option). Unlike the beef and dairy cost model, total confinement was
assumed for all swine and poultry operations; thus, runoff generation was not calculated.
2-11
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Model Farms
based oa preset Characteristics
• stetor, sate, refiion, land
• regulatory option
{•re-processor Sub-RoutiBtt
* .get number of model 6mw
• manure and nutrient characteristics |
- nitttient application rates •
^••l»»»
: Other data KES that j
! provide constants and J
{ costs for the various |
| regions, sties, and |
: sectors • i
I«MBV»I»1
Baric Calculations
•Manure Production
•Nutrient Productson
•Nutrients Required on Farm
• Excess Nutrient Production
Out Sito-Rondhw for Piadktt
tarion/Sefter Snedfte Costs Reekm/SMtOf NoH^ptdfie
> Frequency of Compliance • Constants {ground wsta-
> Nutrient Management Planning rnonhorlng, labor rates, etc.)
> Fadflty Upgrades
- Nutrient Reduction
Modd Outputs
* one page per mode!
* one line per model
> for the 7 regulatory options
Figure 2.2-1. Flow Chart of Swine and Poultry Cost Model
2-12
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The cost model developed costs tfor multiple model farms based on their size,
region; operation type (e.g., type of animal raised), and nutrient (nitrogen or phosphorus) used in
nutrient planning. Costs are calculated for nutrient management planning (e.g., training, soil
testing), facility upgrades (e.g., mortality composting facility, lagoon liner, buffers), land . - -
application, and a range of scenarios for reducing excess nutrients (e.g., separation and hauling,
feeding strategies). Frequency factors are applied to the component costs to weight the costs by
the estimated percentage of operations that already have the component in place. Costs include
capital costs; fixed, one-time costs;'nonannual but recurring costs; and annual costs, all in 1997
dollars. ......
Model components and operations are described in greater detail in the following
subsections. In addition, Section 8.0 describes side analyses conducted to test the sensitivity of
the model to various inputs, to determine the factors that drive the costs, and to evaluate the
overall robustness of the model.
2.2.1
Input Data to Cost Model
Input data to the cost model include information on the model farms, manure and
wastewater generation and characteristics, regional information, technology costs, technical .
characteristics and performance, and frequency factors, as described below. Two types of data
file structures — fixed-format files (*.dat) and variable-format files (*.csv) — are used, and data
elements are separated by commas.
Model farm definitions - Animal type, EPA regulatory option number,
operation type (e.g., broiler, farrow to finish, wet layer), size class (e.g.,
Large 1), average number of head, region, performance level (high,
medium, low), nutrient management basis (N or P), land availability
category (1, 2, or 3), acreage, manure management system (e.g., liquid,
solid), and number of operations that are represented by the model.
Manure and waste generation and* characteristics - Animal turnover rate,
average weight of animal, manure characteristics, weight of manure
produced, volume of manure produced, moisture content of fresh manure,
nitrogen in fresh manure, efficiency of nitrogen application to field,
2-13
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phosphorus in fresh manure, efficiency of phosphorus application to field,
potassium in manure, efficiency of potassium application to field, dilution
factor, percentage of birds that die in one turnover of animals, animal life
span, average weight of animals at death, etc.
Regional information - Recoverable manure correction factors, nitrogen
uptake, phosphorus uptake, transportation distance, chronic rainfall, etc.
Technology costs (including labor) - Installing ground-water monitoring
well; time to sample ground-water monitoring well; water sample analysis;
assessment of crop field/ground water link to surface water; recordkeeping
and reporting; training and certification to land apply manure; manure
sampler; manure nutrient analysis; setup and tune required to take first
, manure sample; time required for additional samples; soil sampling , j 1
frequency—low end; soil sampling frequency—site-specific approach; soil
auger; time required to take sample—low end; time required to take
sample—site-specific approach; cost of soil analysis; rate for obtaining a
certified CNMP; scale to calibrate manure spreader; time required to
calibrate manure spreader; tarp to calibrate manure spreader; hourly tractor
operation costs; general labor rate; professional labor rate; amortization
rate; property tax; standard maintenance; time allowance for litter transfer
to storage; tune allowance for litter storage cleaning; bulk price for wood
shavings; lagoon depth marker; time required for weekly visual inspection;
liner material; insulated lagoon cover; unit area cost of litter storage
facility; phosphorus feeding strategy cost per pig; phosphorus feeding
strategy cost per chicken; nitrogen feeding strategy cost per pig; nitrogen
feeding strategy cost per chicken; hauling and applying liquid manure;
hauling and applying solid manure; solid/liquid separator; pipe; installing a
steel storage tank; time required to install pipe and set up separator; retrofit
initial investment; retrofit 1/4-HP motor per 1,250 swine; retrofit motor
usage per day; electricity; retrofit labor required; retrofit blades required
per year; unit cost of high-rise construction; high-rise fuel, repairs, and
utilities; hoop structure construction; hoop feed and manure equipment;
hoop bedding; hoop fuel, repairs, and utilities; hoop labor, etc.
Technology characteristics and performance - Shaving material application
depth, rate of litter storage cleaning, length of litter storage, lagoon depth,
lagoon side slopes, diversion berm top width, diversion berm height,
diversion berm side slope, cost to move earth, area of house, nitrogen
reduction in manure from feeding strategies,- phosphorus reduction in
manure from feeding strategies, separation safety factor, separator
efficiency, solids content of separated manure, pipe length to connect
lagoon to separator, amount of phosphorus transferred after separation,
amount of nitrogen transferred after separation, etc.
2-14
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Frequency factors - Frequencies at which practices are currently
implemented on model farms.
„ .. Jhe central data file for model farms contains 14,346 records covering the range of
values for animal type, operation type, region, nutrient management basis, baseline management
level, land availability category, regulatory option, manure type, and operation size class.
Separate costs were developed for each of these records (summarized in Table 2.2.1-1). Section
4.0 discusses inputs to the cost model in greater detail.
2.2.2
Technology Calculations
Execution of the cost model begins with a series of routines to load the input data
described in Section 2.2.1. The Main program uses the regulatory option value to set rules
regarding which practices the cost model will use. For example, only Option 3 includes costs for
additional ground water protection practices. Next, the program executes a number of basic
calculations, including total manure generation, nutrient (nitrogen and phosphorus) generation,
and alternative technologies to reduce total nutrient generation, such as feeding strategies.
Another series of calculations follows to determine the land required to spread
manure. These calculations are keyed to one of the following land availability categories:
• Category 1: Farm has the acreage needed to agronomically apply the
nutrients in manure generated at the farm using regional estimates of crop
uptake and yield. This acreage does not include the area of the buffer strip.
• Category 2: Farm has some land, but not enough to agronomically apply
all nutrients in manure generated at the farm.
Category 3: Farm has no land available for application of manure.
2-15
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Table 2.2.1-1
Swine and Poultry Model Farm Input Records
1, .
*, 3 * !. t
Operation Type
and Region
Broilers
Mid-Atlantic
South
Layers - Wet
South
Layers - Dry
Midwest
South
Turkeys
Mid-Atlantic
Midwest
=====
.Options/
Suboptions'
==^==
Land
Availability
Categories
=====
Size
Classes
=======
Nutrient
Management
Bases6
*
12
12
3
3
5
5
'" 2 '
2
i
Manure
Types
1
1
=====
BMP
Imp.
Levels
3
3
12
12
12
12
12
3
2
3
3
5
5
2
2
' 2
3
3
4
4
2
2
1 1 3
i ;
i
i
i
3
3
3
3
Swine - Grow-to-Finish
Central
Mid-Atlantic
Midwest
13
13
13
3
3
3
2
5
5
2
2
2
i
2
2
3
3
3
Sv-'inr. . Farrnw-tn-Finish
Central
Mid-Atlantic
Midwest
13
13
13
3
3
3
2
5
5
2
2
2
1
2
2 '
3
3
3
=====
Total
1,890
945
945
378
378
1,890
945
945
1,512
756
756
4,338
414
1,962
1,962
4,338
414
1,962
1,962 1
14,346 1
Option 6 is for swine only; N and P basis, liquid and pit for two regions, evaporative pond for one region, two sizes and
Options 1 and 1 A are N-based only, whereas option 2A is P-based only.
2-16
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Next, the cost model determines nutrient management planning costs, which
include fixed one-time costs (e.g., engineering costs, soil augers), nonannual recurring costs (e.g.,
CNMP development), and annual costs (e.g., recordkeeping). Some of these costs (e.g., soil
testing) are incurred by all Category 1 and 2 farms, but not by Category 3 farms because they
have no land. '
After calculating nutrient management planning, the cost model calculates facility
upgrade costs. Fixed, one-time costs include both amortizable and nonamortizable costs.
Recurring costs for facility upgrades include visual inspection and operation and maintenance of
the various upgrades. Fixed costs include mortality composting facilities, storage for solid waste,
lagoon depth markers, stormwater diversions (berms), lagoon liners, buffers, recycling pumps,
larger lagoons, and digesters (swine only, Option 6). The cost of storage for liquid waste is
included only in the cases where increased storage is needed to contain chronic rainfall events
(regulatory Option 1 A) or where secondary lagoons are included to address hauling costs
(Category 2 farms). In all other cases, the storage facility design is used only to derive costs for
liners, covers, and storm water diversions. Storage costs in these cases are set to zero because it
is assumed that the storage already exists.
The cost model then evaluates a series of 18 scenarios are then evaluated to
determine the least cost alternative for addressing excess manure nutrients at Category 2 farms.
These scenarios include the initial and annual costs for: feeding strategies; hauling with and
without feeding strategies; separation and hauling with and without feeding strategies; retrofit
flush to scrape (swine operations and wet layer operations); 5-year recurring sludge hauling with
and without feeding strategies (swine operations); high-rise houses (swine operations), including
hauling with and without feeding strategies; hoop houses (swine operations), including hauling
with and without feeding strategies; and lagoon covers, with and without biogas generation and
capture (swine operations).
2-17
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Costs calculated, for ithe.various technologies are included under ;each option for
which the technology applies': the cost rriodei then conducts a cost test to determine the set: of
technologies that produces the lowest cost for each option, using the following equation:
Annualized Model Farm'Cost = 0.14 x Capital Cost + O&M + Fixed + Recurring Cost ^ + Recurring Cost p^
Outputs include fixed, fixed amortized, and annual nonamortized costs for facility
upgrades, land application, and nutrient management for each of the model farms for swine and
poultry. The cost model determines the total cost of each option by multiplying the costs of each
model farm by me-number of farmsite-modd represents. Totals can be generated for each animal
type, operation type, and other distinguishing characteristics by summing the costs across the
selected characteristic. '• ••"• " ; ' ' ! !
••• Figure 2.2.2-2 illustrates the set of practices included in the costing tinder Option
2A,'ph0sphorus-b£ised nutrient management. All costs for nutrient management planning and
facility upgrades are'included in the cost for all options, but the components of these two cost
categories can differ across categories and options. For example, manure sampling devices
included for all farms under Option 2A, but soil testing is not included for Category 3 farms
because they have no land. The cost model calculates costs for all of the technology options
listed in Figure 2:2.2-1, including options to haul manure with and without feeding strategies, and
then selects the cheapest option as described above.
are
2.2.3
Frequency Factors
EPA developed frequency factors that describe the percentage of the swine and
poultry industries that already implements particular operations, techniques, or practices that my
be used to comply with the option. These particular operations, techniques, or practices are not
required by the regulation. Rather, they serve as the cost basis for estimating compliance costs for
specific model farms. The resulting weighted farm costs can be multiplied by the number of
facilities represented by each model to estimate industry-wide costs.
2-18
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Manure sampling device
Manure testing
Nutrient management planning
Nutrient Management Planning
All Farms
Training and certification for manure application
Initial CNMP development
CNMP planning every 3 years
Soil auger
Soil testing
Scale to calibrate manure spreader
Labor and tarp to calibrate manure spreader
Facility Upgrades
Storage for poultry (dry)
Lagoon depth marker (liquid)
Storm water diversions around structures
Visual inspection of facilities
Operation and maintenance for diversions
Buffer
Buffer operation and maintenance
Buffer land rental
Technology Options
Feeding strategies (except for broilers)
Separators (liquid only)
Retrofit scrapers (liquid only)
High-rise house (liquid only)
Hoop house (liquid only)
Lagoon cover with flare (liquid and evaporative)
Hauling
Category 1 and 2
All Farms
Category 1 and 2
All Farms
Category 2 and 3
Figure 2.2.2-1 Practices Included Under Option 2A, Phosphorus-Based Management
2-19
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USDA provided data from which some frequency factors were developed. Where
data from USDA were not available, EPA used frequency factors obtained from other sources,
which vary by sector, component, or practice. Industry and USDA data were used as the basis
for most of the frequency factors for layers and swine; analysis of state and federal regulations
was used primarily for broilers and turkeys. EPA's report on state regulatory programs (USEPA,
1999) was also used for all animal sectors. Costs were not attributed, to CAFO model farms when
state regulations specify standards or require practices equal to or more stringent than the
proposed technology options.
Because the literature and industry-provided data for the broiler and turkey sectors
generally not detailed enough to generate frequency factors, EPA reviewed the specific
;gulatory language and summaries of regulations for 12 major poultry-producing states regarding
requirements for nutrient management plans (NMPs) at broiler and turkey farms (Tetra Tech,
2000). Requirements were considered for farms in two size groups: 300 to 1,000 animal units
(AU) and greater than 1,000 AU. All broiler and turkey farms were assumed to use dry waste
management systems. Detail on the frequency factor calculations is provided in Section 6.
were
re,
2.2.4
Calculation of Weighted Costs
EPA applied the frequency factors to develop a weighted-average cost for each
model farm. For example, if a practice costs $100 and 60 percent (the frequency factor) of the
operations hi the model category already implement the practice, the average cost to farms
represented by that model farm is $40. Each of these weighted-average costs was then multiplied
by the number of farms represented by the particular model farm to estimate industry-level costs.
Varying farm performance was addressed by assigning 25 percent of represented farms to the high
performance level, 50 percent to the medium level, and 25 percent to the low level. As described
above, these levels have different frequency factors values.
The following equation was used to weight the component costs:
= Costcomponent x (1 - Frequency Factor)
2-20
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where:
C°Stweighted
,..., Frequency Factor
Weighted component cost
Component cost , .- > ..
Percentage of operations that have component in
place.
2.3
References
Tetra Tech. 2000. Frequency Factors for Broiler and Turkey Facilities, Memorandum from
Terra Tech, Inc., to Paul Shriner, Work Assignment Manager, U.S. Environmental
Protection Agency, March 3,2000. EPA Contract 68-C-99-263, Work Assignment B-04.
USEPA^1999. State Compendium: Programs and Regulatory Activities Related to Animal
Feeding Operations - Interim Final Report. U.S. Environmental Protection Agency
Office of Water, Washington, DC. '
2-21
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3.0
DATA SOURCES
EPA collected and evaluated data from a variety of sources during the course of
developing the costs for the revised effluent limitations guidelines and standards for the
concentrated animal feeding operations (CAFO) industry. These data sources include EPA site
visits, industry trade associations, the U.S. Department of Agriculture (USDA), published
literature, and data collected and analyzed conducted by the National Climate Data Center
(NCDC), as well as previous EPA Office of Water studies of the Feedlots Point Source Category
and other EPA studies of animal feeding operations. These data sources are discussed below.
The list of references for each section of the cost model report is provided at the end of each
section.
3.1
Summary of EPA's Site Visit Program
The Agency conducted approximately 116 site visits to collect information about
animal feeding operations (AFOs) and waste management practices. Specifically, EPA visited
beef feedlots, dairies, and swine, poultry, and veal operations throughout the United States. In
general, the Agency visited a wide range of operations, including those demonstrating centralized
treatment or new and innovative technologies. EPA chose the majority of facilities with the
assistance of the following industry trade associations:
National Pork Producers Council;
United Egg Producers and United Egg Association;
National Turkey Federation;
National Cattlemen's Beef Association;
National Milk Producers Federation; and
Western United Dairymen.
EPA also received assistance from environmental groups, such as the Natural
Resources Defense Council and the Clean Water Network. The Agency contacted university
experts/state cooperatives and extension services, and state and EPA regional representatives
3-1
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when identifying facilities for site visits. EPA also attended USDA-sponsored farm tours, as well
as industry, academic, and government conferences.
Table 3-1 summarizes the number of site visits EPA conducted by animal industry
sector, site locations, and size of animal operations.
Table 3-1
Number of Site Visits Conducted by EPA for the
Various Animal Industry Sectors
Animal Type
•••^•••••••••i
Swine
Poultry
Dairy
Beef
Veal
Number of Site
Visits
30
6 (broiler)
12 (layer)
6 (turkey)
29
30
Locations)
NC, PA, OH, IA, MN, TX, OK, UT
GA, AR, NC, VA, WV, MD, DE, PA,
OH, IN, WI
PA. FL. CA, WI, CO, VA
TX, OK, KS, CO, CA, IN, NE, IA
, IN
Size of Operaitions
900 - 1 million head
20,000 - 1 million
birds
40 - 4,000 cows
500 -120,000 head
500 - 540 calves
The Agency considered the following factors when identifying representative facilities for site
visits:
• Type of animal feeding operation;
• Location;
• Feedlot size; and
• Current waste management practices.
Facility-specific selection criteria are contained in site visit reports (SVRs)
prepared for each facility visited by EPA. The SVRs are located in the administrative record for
this rulemaking.
3-2
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During the site visits, EPA typically collected the following types of information:
General facility information, including size and age of facility, .number of
employees, crops grown, precipitation information, and proximity to
nearby waterways;
Animal operation data, including flock or herd size, culling rate, and
method for disposing of dead animals;
Description of animal holding areas, such as barns or pens, and any central
areas, such as milking centers;
collection and management information, including the amount
generated, removal methods and storage location, disposal information,
and nutrient content;
Wastewater^collection and management information, including the amount
generated, runoff information, and nutrient content;
•••"-. . Nutrient management plans and best management practices (BMPs); and
• Available wastewater discharge permit information.
/ '. •
This information, along with other site-specific information, is documented in the
SVRs for each facility visited. Some of the information collected from the site visits was used in
the cost model, such as the-percentage of beef feedlots and heifer operations that require the
installation of a pond and the percentage of dairies that would require the installation of a lagoon.
3.2
Industry Trade Associations
EPA contacted the following industry trade associations and representatives during
the development of the proposed and promulgated rules and used the information provided for the
cost model.
US Poultry and Egg Association OJSPOTJT.TRV) USPOULTRY represents all
segments of the poultry and egg industry, from producers of eggs, turkeys, and broilers to the
processors of these products and allied companies that serve the industry. USPOULTRY
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sponsors the world's largest poultry industry show, scientific research, and a comprehensive,
year-round educational program for members of the industry.
Capitol Link. Capitol Link represents the interests of many livestock organizations
and acts as a liaison with federal agencies such as EPA. They frequently provide comments and
data on proposed federal regulatory actions..-
National Pork Pinners Council (NPPQ. NPPC is a marketing organization and
trade association made up of 44 affiliated state pork producer associations. NPPC's purpose is to
increase the quality, production, distribution, and sales of pork and pork products.
United Egg Producers and United Egg AssoHation (UEP/UEA). UEP/UEA
promotes the egg industry in the following areas: price discovery, production and marketing
information, unified industry leadership, USDA relationships, and promotional efforts.
National Turkey Federation (NTF). NTF is the national advocate for all segments
of the turkey industry, providing services and conducting activities that increase demand for its
members'products.
National Chicken Council (NCQ. NCC represents the vertically integrated
companies that produce and process about 95 percent of the chickens sold in the United States.
The association provides consumer education, public relations, and public affairs support, and is
working to seek a positive regulatory, legislative, and economic environment for the broiler
industry.
National Cattlemen's Beef Association (NCBAV NCBA is a marketing
organization and trade association for cattle farmers and ranchers, representing the beef industry.
National Milk Producers Federation (NMPF). NMPF is involved with milk quality
and standards, animal health and food safety issues, dairy product labeling and standards, and
legislation affecting the dairy industry.
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American Veal Association rAVA) AVA represents the veal industry, and
advances the 'industry's concerns in the legislative arena, coordinates production-related issues
affecting the industry, and handles other issues relating to the industry. . ' .-...-
Western United Dairymen (WIJDV WUD, a dairy organization in California,
promotes legislative and administrative policies and programs for the industry and consumers.
Professional Dairy Heifer Growers Association fPDHGA). PDHGAisan
association of heifer growers who are dedicated to growing high-quality dairy cow replacements.
The association offers educational programs and professional development opportunities,
provides a communication network, and establishes business and ethical standards for the dairy
heifer grower industry.
All of the above organizations, along with .several of their state affiliates, assisted
EPA's efforts to understand the industry by helping with site visit selection, submitting
supplemental data, and reviewing descriptions of the industry and waste management practices.
These organizations also participated in and hosted meetings with EPA for the purpose of
exchanging information with the Agency. EPA also obtained copies of membership directories
and conference proceedings, which were used to identify contacts and obtain additional
information on the industry. For the cost model, EPA used information provided by the trade
associations regarding the operations at AFOs and locations of these operations throughout the
U.S. The membership directories for the trade associations were also used.
3.3
U.S. Department of Agriculture (USDA^
EPA obtained data from several agencies within the USDA, including the National
Agricultural Statistics Service (NASS), the Animal and Plant Health Inspection Service (APHIS),
Natural Resources Conservation Service (NRCS), and the Economic Research Service (ERS) in
order to better characterize the AFO industry. The collected data used in the cost model include
statistical survey information and published reports. Data collected from each agency are
described below.
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3.3.1
National Agricultural Statistics Service (NASS)
NASS is responsible for objectively providing accurate statistical information and
data support services of structure and activities of agricultural production in the United States.
Each year NASS conducts hundreds of surveys and prepares reports covering virtually every facet
of U.S. agricultural publications. The primary source of data is the animal production facility.
NASS collects voluntary information using mail surveys, telephone and in-person interviews, and
field observations. NASS is also responsible for conducting a Census bf Agriculture, which is
currently performed once every 5 years; the last census occurred in 1997. EPA gathered
information from the following published NASS reports:
I ,.:•"., j ... i - ,
• Hogs and Pigs: Final Estimates 1993-1997;
• Chickens and Eggs: Final Estimates 1994- 1997;
• Poultry Production and Value: Final Estimates 1994 - 1997;
Cattle: Final Estimates 1994 - 1998;
• Milking Cows and Production: Final Estimates 1993 - 1997;
• 1997 Census of Agriculture; and
• Estimation of Private and Public Costs Associated with Comprehensive
Nutrient Management Plan Implementation: A Documentation, 2002.
The information EPA collected from these sources is summarized below.
Hoes and Pips: Final Estimates 1993 - 1997
EPA used data from this report to augment the swine industry profile. The report
presents information on inventory, market hogs, breeding herd, and pig crops. Specifically, the
report provides the number of farrowings, sows, and pigs per litter. This report presents the
number of operations with hogs; however, EPA did not use this report to estimate farm counts
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because the report provided limited data. Instead, EPA used the 1997 Census of Agriculture data
to estimate farm counts, as discussed later in this section.
Chickens andEsss: Final Estimates 1994 - 1997
EPA used data from this report to augment the poultry industry profile. The
report presents national and state-level data for the top-producing states on chickens and eggs,
including the number laid and production for 1994 through 1997.
Poultry Production and Value: Final Estimates 1994 - 1997
EPA used data-from this report to augment the poultry industry profile. The
report presents national and state-level data for the top-producing states on production (number
and pounds produced/raised), price per pound or egg, and value of production of broilers,
chickens, eggs, and turkeys for 1994 through 1997.
Cattle: Final Estimates 1994 - 1998
f
EPA used data from this report to augment the beef industry profile. The report
provides the number of and population estimates for beef feedlots that have a capacity of over
1,000 head of cattle, grouped by size and geographic distribution. This report provides national
and state-level data, which include the number of feedlots, cattle inventory, and number of cattle
sold per year by size class for the 13 top-producing beef states. The report also provides the total
number of feedlots that have a capacity of fewer than 1,000 head of cattle, total cattle inventory,
and number of cattle sold per year for these operations. However, EPA did not use this report to
estimate farm counts because the report provided limited data. Instead, as discussed earlier in this
section, EPA used the 1997 Census of Agriculture data to estimate farm counts, as discussed later
in this section.
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Milkinz Cows and Production: Final Estimates 1993 - 1997
EPA used data from this report to augment the dairy industry profile. The report
presents national and state-level estimates of dairy cattle inventory and the number of dairy
operations by size group. This particular report presents data for all dairy operations with over
200 mature dairy cows in.one size class. However, EPA did not use this report to estimate.farm
counts because the report provided limited data. Instead, EPA used the 1997 Census of
Agriculture data to estimate farm counts, as discussed below.
1997 Census of Agriculture •. .
The Census of Agriculture is a complete accounting of U.S. agricultural
production and is the only source of uniform, comprehensive agricultural data for every county in
the nation. The census is conducted every 5 years. Prior to 1997, the Bureau of the Census
conducted this activity. Starting with the 1997 Census of Agriculture, the responsibility passed to
USDA NASS. The census includes all farm operations from which $1,000 or more of agricultural
products are produced and sold. The most recent census occurred in late 1997 and is based on
calendar year 1997 data.
The census collects information relating to land use and ownership, crops,
livestock, and poultry. This database is maintained by USDA; data used for this analysis were
compiled with the assistance of staff at USDA NASS. (USDA periodically publishes aggregated
data from these databases and also compiles customized analyses of the data for members of the
public and other government agencies. In providing such analyses, USDA maintains a sufficient
level of aggregation to ensure the confidentiality of any individual operation's activities or
holdings.)
Several size groups were developed to allow tabulation of farm counts by fairm size
using different criteria than those used in the published 1997 Census of Agriculture. EPA
developed algorithms to define farm size in terms of capacity, or number of animals likely to be
found on the farm at any given time. To convert sales of hogs and pigs and feeder pigs into an
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inventory, EPA divided total sales by the number of groups of pigs likely to be produced and sold
in a given year. EPA estimates that the larger grow-finish farms produce 2.8 groups of pigs per
year. ; Farrow-finish operations produce 2.0 groups of pigs per year. Nursery operations produce
up to 10 groups per year. Data used to determine the groups of pigs produced per year were
obtained from a survey performed by USDA (USDA APHIS, 1999).
For beef operations, EPA estimates the larger feedlots produce up to 3 .5 groups of
cattle per year, while the smaller operations produce only 1 to 1.5 groups per year (ERG, 2002).
The newly aggregated data better depict the size and geographic distribution of operations needed
for EPA's analysis, particularly smaller beef feedlots (fewer than 1,000 head capacity) and larger
dairies (more than 200 mature dairy: cows). EPA used the census data to gather more details on
the larger dairies, such as the number of operations and number of head for additional size classes
(200 to 499, 500 to 999, and more than 1,000'head).
'"
also compiled and performed analyses on census data thatEPAused
for its analyses. These data identify the number of feedlots, their geographical distributions, and
the amount of cropland available to land apply animal manure generated from their confined
feeding operations (based on nitrogen and phosphorus availability relative to crop need). EPA
used these estimates to identify feedlots that may not own sufficient land to apply all of the animal
manure to the land. EPA used the results of this analysis to estimate the number, of operations
that may incur additional manure transportation costs under the various regulatory options
considered under the proposed rule.
Estimation of Private and Public Costs Associated with Comprehensive Nutrie
Management Plan Implementation: A Documentation. 2002
EPA received data from USDA as part of a document entitled Estimation of
Private and Public Costs Associated with Comprehensive Nutrient Management Plan
Implementation: A Documentation. This document presents costs and frequency factors for three
performance-based categories of facilities (low requirement, medium requirement, and high
requirement) for a series of "representative" farms defined by USDA in nine USDA-defined
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regions. This approach is similar to EPA's modeling approach, and allowed EPA to directly use
some of USDA's data to calculate corresponding frequency factors in the cost models.
3.3.2
Animal and Plant Health Inspection Service (APHIS)/National Animal
Health Monitoring System (NAHMS)
APHIS provides leadership in ensuring the health and care of animals and plants,
improving agricultural productivity and competitiveness, and contributing to the national economy
and public health. One of its main responsibilities is to enhance the care of animals. In 1983,
APHIS initiated the National Animal Health Monitoring System (NAHMS) as an information-
gathering program to collect, analyze, and disseminate data on animal health, management, and
productivity across the United States. NAHMS conducts national studies to gather data and
generate descriptive statistics and information from data collected by other industry sources.
NAHMS has published national study reports for various food animal populations (e.g., swine,
dairy cattle).
reports:
EPA gathered information for the cost model report from the following NAHMS
Swine '95 Part I: Reference of 1995 Swine Management Practices;
Swine '95 Part II: Reference of Grower/Finisher Health & Management
Practices;
Swine 2000 Part I: Reference of Swine Health and Management in the
United States;
Layers '99 Parts I and II: Reference of 1999 Table Egg Layer
Management in the U.S.;
Dairy '96 Part I: Reference of 1996 Dairy Management Practices;
Dairy '96 Part III: Reference of 1996 Dairy Health and Health
Management;
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• Beef Feedlot '95 Part I: Feedlot Management Practices; and
• Feedlot '99 Part I: Baseline Reference of Feedlot Management Practices.
=•„ EPA also collected information from NAHMS fact sheets, specifically the Swine.
'95 fact sheets, which describe biosecurity measures, vaccination practices, environmental
practices/management, and antibiotics used..iii-the industry.
Swine '95 Part I: Reference of 1995 Swine Management Practices
- -•-•-- This^report provides references on productivity, preventative and vaccination
practices, bioseciirity"issues, and environmental programs (including carcass disposal). The data
were obtained from a sample of "1,477 producers representing nearly 91 percent of the U.S. hog
inventory from the top 16 pork-producing states. Population estimates are broken down into
farrowing and weaning, nursery, grower/finisher, and sows. ,
Swine '95 Part II: Reference of Grower/Finisher Health & Management Practices
This report provides additional references on feed and waste management, health
and productivity, marketing, and quality control. • the data were collected from 418 producers
with operations having 300 or more market hogs (at least one hog over 120 pounds) and
represent about 90 percent of the target population. NAHMS also performed additional analyses
for EPA that present manure management information for the swine industry by two size classes
(fewer.than 2,500 marketed head and more than 2,500 marketed head) and three regions
(Midwest, North, and Southeast) (USDA APHIS, 1999).
Swine 2000 Part I: Reference of Swine Health and Manasement in the United
States .
Swine 2000 was designed to statistically sample from operations with 100 or more
pigs. The study included 17 of the major pork-producing states that account for 94 percent of the
U.S. pig inventory. Data for this report were collected from 2,328 operations. This report
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provides information on feed and waste management, health and productivity, animal
management, and facility management. In addition to this report, NAHMS also performed
additional analyses for EPA that present the percentage of sites where pit holding was the waste
management system used most by region and herd size for the farrowing and grow/finish phase
(USDA APHIS, 2002).
Layers '99 Parts I and II: Reference of 1999 Table Ess Layer Management in the
XheJLayers.99 study is the, first NAHMS national study of the .layer industry,
Data were obtained from 15 states, which account for over 75 percent of the table egg layers in
the United States. Part I of this report provides a summary of the study results, including
descriptions of farm sites and flocks, feed, and health management. Part II of this report provides
a summary of biosecurity, facility management, and manure handling. .
Dairy '96 Part I: Reference of 1996 Dairy Management Practices and Dairy '96
Part III: Reference of 1996 Dairy Health and Health Management
These reports present the results of a survey that was distributed to dairies in 20
major states to collect information on cattle inventories; dairy herd management practices; health
management; births, illness, and deaths; housing; and biosecurity. The results represent 83
percent of U.S. milk cows, or 2,542 producers. The reports also provide national data on cattle
housing, manure and runoff collection practices, and irrigation/land application practices for
dairies with more than 200 or fewer than 200 mature dairy cows. NAHMS provided the same
information to EPA with the results reaggregated into three size classes (fewer than 500, 500 to
699, and more than 700 mature dairy cows) and into three regions (East, West, and Midwest).
BeefFeedlot '95 Part I: Feedlot Management Practices
This report contains information on population estimates, environmental programs
(e.g., ground-water monitoring and methods of waste disposal), and carcass disposal at small and
' 3-12
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large beef feedlots (fewer than and more -than 1,000 head capacity). The data were collected from
3,214 feedlots in 13 states, representing almost 86 percent of the U.S. cattle-on-feed inventory:
'• i
'' '•'• "' "• feedlot '99 Parti: Baseline Reference ofFeedlot Management Practices
This report also contains information on population estimates, environmental
programs, and carcass disposal at beef feedlots. The data were collected from 1,250 feedlots in
12 states, representing 77 percent of all cattle on feed in the United States.
3.3.3
Natural Resources Conservation Services (NRCS)
NRCS provides leadership in a partnership effort to help people conserve,
improve, and sustain our natural resources and the environment. NRCS relies on many partners
to help set conservation goals, work with people on the land, and provide assistance. Its partners
include conservation districts, state and federal agencies, NRCS Earth Team volunteers,
agricultural and environmental groups, and professional societies.
NRCS publishes the Agricultural Waste Management Field Handbook, which is
an agricultural/engineering guidance manual that explains general waste management principles,
and provides detailed design information for particular waste management systems. The
handbook reports specific design information on a variety of farm production and waste
management practices at different types of feedlots." The handbook also reports runoff
calculations under normal and peak precipitation as well as information on manure and bedding
characteristics. EPA used this information to develop its cost and environmental analyses. NRCS
personnel also contributed technical expertise in the development of EPA's estimates of
compliance costs and environmental assessment framework by providing EPA with estimates of
manure generation in excess of expected crop uptake.
NRCS also analyzed the census data that EPA used for its analysis. In the draft
February 23, 2002 Profile of Farms with Livestock in the United States: A Statistical Summary
USDA NRCS presents estimates of the number of CAFOs by animal sector and size group, as
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well as the number of head at these farms. EPA used these estimates to calculate the average
number of head and the number of CAFOs by animal sector and size group. In the case of beef
feedlots, NRCS used a turnover rate of 2.5 to estimate capacity for all size operations. EPA
recalculated the number of head at these operations using the turnover rates discussed above.
Another NRCS report, Manure Nutrients Relative to the Capacity of Cropland
and Pastureland to Assimilate Nutrients:-Spatial and Temporal Trends for the United States
published in December 2000, provides background information on trends in animal agriculture
and manure production based on information collected in the 1997 Census of Agriculture. EPA
used data on the percentage of farms with sufficient cropland, insufficient cropland, and no
cropland to determine the number of CAFOs that require off-site transport of excess manure.
EPA also used data from this report to determine the amount of excess manure at operations with
an insufficient amount of cropland to agronomically land apply all of the manure and wastewater
generated on site.
Beginning in early 2002, NRCS shared drafts of its report Overview of Cost
Analysis for Implementation of CNMPs On Animal Feeding Operations with EPA. This report
presents a cost analysis for planning, designing, implementing and following up on CNMPs on
AFOs. The report also estimated the percentage of operations that have high, medium, and low
requirements for the development and implementation of CNMPs. The scheduled release of the
final document was October 2002. EPA used information from this report to refine baseline
conditions of the CAFOs industry.
3.3.4
Agricultural Research Service (ARS)
ARS is the primary research agency working internally for the USD A. One of its
many objectives is to heighten awareness of natural resources and the environment. EPA used
information provided from ARS's Agricultural Phosphorus and Eutrophication report (USDA
ARS, 1999) to estimate the number of CAFOs that could be subject to a phosphorus-based
regulation.
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3.3.5
Economic Research Service (ERS)
ERS provides economic analyses on efficiency, efficacy, and equity issues related
to agriculture, food, the environment, and rural development to improve public and private
decision making. ERS uses data from the Farm Costs arid Returns Survey (FCRS) to examine
farm financial performance (USDA ERS, 1997). This report developed 10 regions that were
intended to group agricultural production into fooad geographic regions of the United States:
Pacific, Mountain, Northern Plains, Southern Plains, Lake States, Corn Belt, Delta, Northeast,
Appalachian, and Southern. EPA further consolidated the 10 sectors into 5 regions in order to
analyze aggregated Census of Agriculture'data. -
n -. - ,
ERS is also responsible for the Agricultural Resource Management Study
(ARMS), USDA's primary vehicle for collection of information on a broad range of issues about
agricultural resource use and costs and farm sector financial conditions. The ARMS is a flexible
data collection tool with several versions and uses. Information is collected via surveys, and it
provides a measure of the annual changes in the financial conditions of production agriculture.
3.4
Literature Sources
i sources
EPA performed several Internet and literature searches to identify papers,
presentations, and other applicable materials to use in the cost model report. Literature SL
were identified from library literature searches as well as through EPA contacts and industry
experts. Literature collected by EPA covers such topics as housing equipment, fertilizer and
manure application, general agricultural waste management, air emissions, pathogens, and
construction cost data. EPA used literature sources to estimate the costs of design and expansion
of waste management system components at AFOs. EPA also used publicly available information
from several universities specializing in agricultural research for industry profile information,
waste management and modeling information, and construction cost data, as well as existing
computer models, such as the FarmWare Model that was developed by EPA's AgStar program.
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3.5
National Climate Data Center fNCDQ
EPA used data from another government agency, the National Climate and Data
Center (NCDC). The National Oceanic and Atmospheric Administration (NOAA) conducts
research and gathers data, which is provided on the NCDC web site. For the cost model, EPA
used the Normal Monthly Precipitation report from the NCDC web site to obtain the normal
monthly precipitation values from 1971 to 2000 for cities in each state. These values were used
to calculate the annual precipitation for each region.
3.6
References "
ERG, 2002. Beef Production Cycles and Capacity. Memorandum from D. Bartram to Feedlots
Rulemaking Record. December 9, 2002.
ERG, 2000. Facility Counts for Beef, Dairy, Veal, and Heifer Operations. Memorandum by
Deborah Bartram, Eastern Research Group, Inc. to the Feedlots Rulemaking Record.
December 13,2002.
USDA ERS, 1997. Farm Costs and Returns Survey (FCRS).
USDA ARS, 1999. Agricultural Phosphorus & Eutrophication (ARS-149). July 1, 1999.
USDA APHIS, 1999. Data summaries of NAHMS Swine '95, prepared at request of EPA.
National Animal Health Monitoring System. Washington, DC.
USDA, 2002. Queries run by Centers for Epidemiology and Animal Health prepared by Eric
Bush; March 22,2002; 2 pages.
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4.0
INPUT DATA
This section describes in detail the input data to the cost model that EPA used to
estimate the' 'compliance costs for CAFOs. Section 4.1 defines the geographic regions that were
modeled, Section 4.2 describes the size groups for each animal group, Section 4.3 discusses farm
counts, Section 4.4 discusses average head at animal feeding operations, Section 4.5 discusses
wastewater/dilution water, Section 4.6 discusses manure generation, Section 4.7 discusses
precipitation data and runoff, Section 4.8 discusses crops and agronomic application rates,
Section 4.9 discusses^excess manure, and .Section 4.10 discusses acres available for land
application of manure.; ~~~'•- •—•'••- ......
4.1
Definition of Regions
For the purposes of this analysis, EPA classified animal feeding operations into
various geographic regions. The Agency used these classifications to differentiate the types of
waste management system components that are expected to be in place at baseline (due either to
existing regulations or to geographic location), as well as the amount of wastes generated, the
crops grown, and the ability of the operations to use manure, litter, and. other process wastewater.
on site. This subsection describes the geographic regions developed and used to estimate
compliance costs for CAFOs.
The cost model addresses variations between operations in different regions of the
country. For example, the crop nutrient removal rates, which are used to set manure application
rates, vary among regions of the country based on average crop yields in each region. Many of
the costs in the model rely on the manure and associated nutrient production of the animals at an
operation, and are affected by regional differences such as climate and rainfall. Some frequency
factors also vary by region when data were available.
EPA generally obtained information on animal production from USDA's 1997
Census of Agriculture, .USD A's National Agricultural Statistics Service (NASS), and information
gathered from site visits and trade associations. For information obtained from the 1997 Census
4-1
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of Agriculture, EPA divided the United States into five production regions and designated them
the South, Mid-Atlantic, Midwest, West, and Central regions. Originally, the USDA Economic
Research Service (ERS) established ten regions so that it could group economic information.
EPA condensed these regions into the five regions because of similarities in animal production and
manure-handling techniques, and to allow for the aggregation of critical data on the number of
facilities, production quantities, and financial conditions, which may otherwise not be possible due
to concerns about disclosure.1 Table 4.1-1 presents the .production regions.
.:..... ,, • ••- :P'= .:*». Table4.1-1 ' • ' ":'" J '
Animal Feeding Operation (AFO) Production Regions
Region
Central
Mid-Atlantic
Midwest
Pacific
South
- - •-'•••. v : >i^> States Included -..•••<-.•...-,',:..->, ••uw-»\--.-;:>;vbv/-,'i ..•..;•,
Arizona, Colorado, Idaho, Montana, Nevada, New Mexico, Oklahoma, Texas, .Utah,
Wyoming
Connecticut, Delaware, Kentucky, Maine, Maryland, Massachusetts, New Hampshire,
Jersey, New York, North Carolina, Pennsylvania, Rhode Island, Tennessee, Vermont,
Virginia, West Virginia
New
Illinois, Indiana, Iowa, Kansas, Michigan, Minnesota, Missouri, Nebraska, North Dakota,
Ohio, South Dakota, Wisconsin
Alaska, California, Hawaii, Oregon, Washington
Alabama, Arkansas, Florida, Georgia, Louisiana, Mississippi, South Carolina
For swine and poultry operations, EPA developed key geographic regions on
which to focus cost modeling efforts because the swine and poultry animal sectors tend to be
concentrated in these regions. Also, data are lacking for those regions where a particular sector
has a lesser presence. The climate of each key region defines the amount of precipitation mat will
need to be managed and the typical evaporation rate. The region also defines typical crop yields,
soil types, housing types, and manure management practices that vary across the nation. In
practice, a given state may have many soil types and climatic variations; EPA adopted the key
'For example, USDA Census of Agriculture data are typically not released unless there are enough observations to
ensure confidentially. Consequently, if data were aggregated on a state basis (instead of a regional basis), many
key data points needed to describe the industry segments would be unavailable.
4-2
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region approach to account for typical geographical variations without using an impractical
number of model farms.
Table 4.1-2 presents the key regions for each animal sector. The Swine 95 survey
found that 78 percent of U.S. hog operations were located in the Mid-Atlantic and Midwest
Regions. However, more recent reports indicate an increasing trend toward large facilities in the
Central Region- Thus, the key regions selected for the swine sector are the Mid-Atlantic,
Midwest, and Central. As described in Chapter 2;~swine operations do not generally collect
runoff, and direct rainfall variations in the other regions does not significantly change costs. To
account for all potentially regulated operations, the cost model distributed operations in regions
other than the key'regions evenly among'the regions that were modeled. For
example, the Midwest region combines operations from the Midwest with a portion of the
operations from the "non-key" regions that are assumed to have similar production and manure
management practices. Large swine operations that use evaporative lagoons for waste storage
were modeled in the Central region. Operations located in other regions were split among the
modeled regions to fully account for operations in a given size class. Allocating operations from
one region to another was necessary since the census data could not be obtained for all desired
regions and size groups (USDA NASS, 1999).
Beef feedlots, dairies, heifer, and veal operations were modeled in all regions in
which operations were identified within EPA's size classes. No Large beef feedlots were identified
in the South region. Additionally, no heifer operations were identified in the Mid-Atlantic and
South regions, no Large heifer operations were identified in the Midwest region, and no veal
operations were identified in the Pacific and South regions. The regions used for each animal
sector are presented in Table 4.1-2.
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Table 4.1-2
Key Regions Modeled by Animal Sector
Animal Sector
Swine: Farrow to Finish
Swine: Grow Finish
Layer. Wet
Layer: Dry
Broiler
Turkey
BeefFeedlots
Dairies
Heifer Operations
Veal Operations
Regions Modeled ;
Mid-Atlantic, Midwest, Central
Mid-Atlantic, Midwest, Central ,
South
Midwest, South
Mid-Atlantic, South
Mid-Atlantic, Midwest
Central, Mid-Atlantic, Midwest, Pacific, South
Central, Mid-Atlantic, Midwest, Pacific, South
Central, Midwest, Pacific
Central, Mid-Atlantic, Midwest
The key regions for broilers are the Mid-Atlantic and South (containing 86 percent
of larger farms), while the Mid-Atlantic and Midwest are the key regions for turkeys (containing
67 percent of larger farms). Layer farms with wet manure systems are located primarily in 'the
South and Texas, where approximately half of all layer farms use wet-manure-handling systems.
EPA used industry reports and NAHMS data to estimate the number of layer farms with wet
manure systems in the rest of the United States (USDA APHIS, 1999). The South and Midwest
are the key regions for all other layer farms, capturing 53 percent of larger layer farms in addition
to the 12 percent of farms with layers with wet manure systems. For large broiler, turkey, and
layer farms (other than wet manure systems), precipitation was not a key factor affecting costs.
These operation use confining housing almost exclusively. Therefore, operations from "non-key"
regions were folded into the key regions for these animal types in the same manner as described
above for swine operations.
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4.2
Definition of Size Groups
EPA developed and analyzed up to five size groups for each animal type. These
size groups included^ne to two "Large" groups, representing operations that are already subject
to the 1974 effluent limitations guidelines and standards for the Feedlots Point Source Category,
as well as three "Medium" groups to evaluate the costs, benefits, and impacts of the regulatory
options on operations that may be defined as CAFOs. Table 4.2-1 presents the size groups for
each animal type.
J Table 4.2-1
Size Classes for Model Farms3 '
^•J&fimal Type
Beef
Heifer
Dairy (Mature
Dairy Cows)
Veal
Swine
Dry Layers
Wet Layers
Broilers
Turkeys
Medium 1
300-499
300-499
200-349
300-499
750-1,249
25,000-49,999
NA
37,750-49,999
16,500-27,499
Medium 2 *
50.0-749
500-749
350-524
500-749
1,250-1,874
50,000-74,999
NA
50,000-74,999
27,500-41,249
Medium 3
750-999
750-999
525-699
£750
1, '875-2,499
75,000-81,999
9,000-29,999
75,000-124,999
41,250-54,999
Large 1,
1,000-7,999
^ 1,000
£700
NA
2,500-4,999
82,000-599,999
>30,000
125,000-179,999
£55,000
Large .2
£8,000,
NA
NA
NA
;>5,000
>600,000
NA
£180,000
"These size classes represent capacity at a given point in the year, which does not necessarily correspond to annual
production.
4.3
Farm Counts
This subsection describes how EPA developed farm counts for each animal sector.
4-5
-------
4.3.1
Farm Counts - Beef Feedlots
Table 4.3.1-1 presents the total number of potential beef CAFOs by size class, as
estimated by USDA's NRCS, using the 1997 Census of Agriculture data (USDA, 2002). The
USDA estimates grouped all large operations (;> 1,000 head) into one group. EPA supplemented
these data with USDA's NASS data to estimate that there are 421 beef feedlots with ;>8,000 head
(USDANASS, 1999b). - : ..
Table 4.3.1-1
Number of Potential Beef CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
1 Size Class (Number of Milk Cows) ;;/..,
Medium 1
(300-499 head)
Medium 2
(500-749 head)
801
Medium 3
(750-999 head)
415
JLarge 1 and 2
(arl?000head)
1,766
total "
7,230
Source: USDA, 2002 (Table 16).
To estimate the number of operations by geographic region, EPA used the number
of operations that sold fattened cattle by state provided in the 1997 Census of Agriculture data to
develop a distribution of beef feedlots by region. Because the Census data are sales numbers,
EPA estimated the number of production cycles per year and converted the sales data into cattle
capacity (i.e., the number of beef cattle estimated on site at any one time) (ERG, 2002). Table
4.3.1-2 presents the distribution of beef feedlots by region for each size category provided In the
Census. Table 4.3.1-2 also presents the estimated cattle capacity for each size category in the
Census.
4-6
-------
Table 4.3.1-2
Percentage of Beef Feedlots by Region and Census of Agriculture Size
• ........ ., .. . . ... .Category ' " " '"""[
~ Region
Census Size
'Categories
Estimated
, Capacity"
Central
Mid-Atlantic
Midwest
Pacific
South ,
Percentage of Beef Feedlots- ' .->
500-999
Head Sold
380-750
.Head Capacity
11.6
3.9 .' '
•'82.5
... 1-4
0.5
1,000-2,499
* Head Sold
750-1,785
Head Capacity
15.2
2.7'
"78.7 • -
.2.7
0.7
2,500-4,999
Head Sold -
1,785-3,424
Head Capacity
21.4
1.6
74.5
2.5
0
-5:5,000
Head Sold -
*3,425 < "
Head Capacity >
36.6
0.2
58.3
5.0
0
;> 1,000 head
-capacity*1
31.5
0.6
63.7 •
4.2
o
source: census or Agnculture (USDA, 1997).
"ERG memorandum (2002.).
'Estimated as the geographic distribution of both the 2,500 to 4,999 and the 2 5,000 head sold categories. '
EPA assumed that the regional distribution of operations for the Medium 1 and
Medium 2 size classes is represented by the 500 to 999 head sold category in the Census and the
regional distribution of operations for the Medium 3 size class is represented by the 1,000 to
2,499 head sold category in the Census. EPA also estimated that the regional distribution for
both the Large 1 and Large 2 size classes is represented by the combination of the 2,500. to 4,999
and the :> 5,000 head sold category (the regional distribution of operations for this size class is
presented in Table 4.3.1-2 under the heading ":> 1,000 head").
For example, EPA estimated the potential number of beef CAFOs in the Central
region by size class using the following equations and the data presented in Tables 4.3.1-1 and
4.3.1-2:
Medium 1:
Medium 2:
Medium 3:
Large 1:
Large 2:
1,466 operations x 11:6% = 170;
801 operations x 11.6% = 93;
415 operations x 15.2% = 63;
1,345 operations x 31.5% = 424; and
421 operations x 31.5% =133.
4-7
-------
Table 4.3.1-3 presents the final number of beef feedlot CAFOs by size class and region.
Table 4.3.1-3
Number of Beef Feedlots by Region and Size Class
Region
Central
Mid-Atlantic
Midwest
Pacific
South
•••• ,.,..-,;•..,. .-•-- ., .SfeeCtassi-. -.-.....• ;-;..:^,'^""-'1.-.?.;.
Medium 1
170
58
1,210
21
7
Medium 2 i
93
32
661
11
4
Medium3.
63
11
327
11
3
: Large!;;
424
8
856
57
0
,targe2
133
3
268
17
0
Not all medium operations are expected to be CAFOs under the rule. The percentage.of medium
facilities EPA estimates will be CAFOs is presented in Table 4.3.1-4 (See Preamble Section 4 and
40 CFR part 122.23).
r Table 4.3.1-4
Percentage of Beef Facilities That Are Expected to Be CAFOs
, Region
Central
Mid-Atlantic
Midwest
Pacific
South
Size Class
All Medium
10
4
6
10
4
All Large
100
100
100
100
10
4-8
-------
4.3.2
Farm Counts - Dairies
Table 4.3.2-.1 presents the total number of potential dairy CAFOs by size class, as
estimated by USDA's NRCS, using the 1997 Census of Agriculture data (USDA NRCS, 2002).":
To estimate the number of operations by geographic region, EPA used the number of milk cow
operations by state provided in the 1997 Census of Agriculture data to develop a distribution of
dairies by region. However, the Census provides farm counts for different size groups than" those
evaluated by EPA, as shown in Table 4.3.2-2. - - > - . ~ .....
Table 4.3.2-1
Number of Potential Dairy CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
, , - Size Class (Number of Milk Cows)
Medium 1
(2flbi349 head)
3,805
Medium 2
(350-524 head)
1,372
Mediums
(525-699 head)
603
Large 1
(;>700 head)
1,450
Total ;.;
7,230 .
source. UOJJA JNKL-a, /UU/ (lame 16).
Table 4.3.2-2
Percentage of Dairies by Region and Census of Agriculture Size Category
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Percentage of Dairies
200-499 head
17.5
25.7
. 27.9
21.3
7.5
500-999 head
20.9
12.5
9.6
49.8
7.2
s 1,000 head
31.9
3.8
4.7
54.0
5.7
;>700head"
27.6
7.1
6.6
52.4
63
Source: Census of Agriculture (USDA, 1997).
'Estimated as 40 percent of operations with 500-999 head and all of operations with s 1,000 head.
4-9
-------
For the purposes of this rule, EPA assumed that the regional distribution of
operations in the Medium 1 and Medium 2 size classes were represented by the 200 to 499 head
category in the Census. EPA also assumed that the regional distribution of operations in the
Medium 3 size-clas.8 were represented by the 500 to 999 head category in the Census. EPA
estimated that 40 percent of operations in the Census '"500 to 999 head category and all of the
operations in the Census' s 1,000 head category .make up the Large 1 size class. The regional ,
distribution of operations for this size class is presented in Table 4.3.2-2 under the heading "^700
head."- — ..... - ••• " " "'•
For example, EPA estimated the number of dairy CAFOs in the Central region by
size class using the following equations and the data presented in fables 4.3.2-1 and 4.3.2-2:
Medium 1: 3,805 operations x'17.5% =667;
Medium 2: . 1,372 operations x 17.5% =241;.;
Medium 3: 603 operations x 20.9% = 126; and
Large 1: ' - 1,450 operations x 27.6% =401.
Table 4.3.2-3 presents the final number of dairies by size class and region.
Table 4.3.2-3
Number of Dairies by Region and Size Class
Region
Central
Mid-Atlantic
Midwest
Pacific
South
•'•••./-••• -Size-Class •..•:•" -.'••-. • " ;, ;•
Medium 1
667
979
1,062
, 812
285
Medium 2
241
353
383
293
102
Medium 3
126
75
58
301
43
Large 1
401
104
95
759
91
Not all medium operations are expected to be CAFOs under the rule. The percentage of medium
operations EPA estimates will be CAFOs is presented in Table 4.3.2-4 (See Preamble Section 4
and 40 CFRpart 122.23).
4-10
-------
Table 4.3.2-4
Percentage of Dairies That Are Expected to Be CAFOs
r Region
Central -
Mid-Atlantic -
Midwest
Pacific
South
Size Class
All Medium
20
• • • 55 -
. 45 .-
10
- • -35
AUJLarge
100
100
100 ~»
100
100
4.3.3
Farm Counts - Heifer Operations
Table 4.3.3-1 presents the total number of potential heifer CAFOs by size, as
estimated by USDA's NRCS, using the 1997 Census of Agriculture data (USDA NRCS, 2002).
To estimate the number of operations by geographic region, EPA reviewed membership data from
the Professional Heifer Growers Association, as well as available data from the Census of
Agriculture. However, none of these sources provided an estimate of operations by both size
class and geographic location. Because heifer operations directly support the dairy industry, EPA
assumed that they are concentrated in areas where the dairy industry is moving toward
specialization (BocherL.W., 1999). Using best professional judgement, EPA estimated that the
majority of large heifer operations are located in the west and south (represented by the Pacific
and Central regions), while the majority of the smallest operations are located in the Midwest.
Table 4.3.3-2 presents EPA's estimated distribution of heifer operations by size class and region.
4-11
-------
Table 4.3.3-1
Number of Potential Heifer CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
Medium 1
(300-499 head)
417
, Steel
Medium 2
(500-749 head)
218
ClaSS i..'''.; :
Medium3
(750-999 head)
89
Lai-gel
"-
-------
Table 4.3:3-3
Number of Heifer Operations by Region and Size Class
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Size Class
-Medium 1
42
0
333
42
0
Medium 2
109
0
44
65
o
Medium 3
44
0
18
27
o
Large 1
• 145
0
0
97
Q
Not all medium operations are expected to be CAFOs under the rale. The percentage of medium
operations EPA estimates will be CAFOs is presented in Table 4.3.3-4 (See Preamble Section 4
and 40 CFR part 122.23).
Table 4.3.3-4
Percentage of Heifer Operations That Are Expected to Be CAFOs
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Size Class
AH Medium
20
55
45
10
35
Alllair-ge - ;
100
100
100
100
100
4.3.4
Farm Counts - Veal Operations
Table 4.3.4-1 presents the total number of potential veal CAFOs by size, as
estimated by USDA's NRCS, using the 1997 Census of Agriculture data (USDA NRCS, 2002).
EPA conducted site visits to veal operations and requested distribution data from industry to
estimate the number of veal operations by size class and region in the United States. These data
indicate that veal producers are located predominantly in the Midwest and Central regions
4-13
-------
(Crouch A., 1999). Using best professional judgement, EPA estimated that the vast majority (95
percent) of operators are located in the Midwest, with the remaining operations located in the
Mid-Atlantic and Central regions. Table 4.3.4-2 presents EPA's estimated distribution of veal
operations by size class and region.
Table 4.3.4-1
Number of Potential Veal CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
1- •• • '-,- "Size Class ;i:-:;., l,-:. ----- \.:;. :;•:.
Medium 1
(300-499 head)
35 ' •
Medium 2
(500-749 nead)f
• 17
Medium, 3
(sTSOhead)4
17
•/Total '-.:;.?;'
69
Source: USDA NRCS, 2002 (Table 16).
•USDA estimates that 12 veal operations are s 1,000 head.
Table 4.3.4-2
Percentage of Veal Operations by Region and Size Class
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Percentage of Veal Operations
Medium 1
2.5
2.5
95
0
0
Medium 2 v
5
0
95
0
0
Medium 3
5
0
95
0
0
For example, EPA estimated the number of veal CAFOs in the Central region by
size class using the following equations and the data presented in Tables 4.3.4-1 and 4.3.4-2:
Medium 1: 35 operations x 2.5% = 1;
Medium 2: 17 operations x 5% = 1; and
Medium 3: 17 operations x 5% = 1.
Table 4.3.4-3 presents the final number of veal operations by size class and region.
4-14
-------
Table 4.3.4-3
Number of Veal Operations by Region and Size Class
Region ;
Central
Mid-Atlantic
Midwest
Pacific
South
'•.-.'.'••..'•/• v'. •,..--:: Size Class :.r>-'.:?^-:v.v
AM«$iuml;>-
1
1
33
0
0
Medium 2
1
0
16
0
o
, Medium^ *
1
0
16
0
Q '
Not all medium operations are expected to be CAFOs under the rule. The percentage of medium
operations EPA estimates will be CAFOs is presented in Table 4.3.4-4 (See Preamble Section 4
and 40 CFR part 122.23). "-
Table 4.3.4-4
Percentage of Veal Operations That Are Expected to Be CAFOs
; Region
Central
Mid-Atlantie
Midwest
Pacific
South
•':•-'••-.•.;_•-•; ,v^: Sjze'XHass , .•;.- • ,' ; -:
^Medium is
10
4
6
10
4
^Medium 2 ;
10
4
6
10
. 4
^Mediums
100
100
100
100
100
4.3.5
Farm Counts - Poultry Operations
Layers
Table 4.3.5-1 presents the total number of layer, layer/pullet, and pullet operations
using the 1997 Census of Agriculture database (USDA NRCS, 2002). Lacking more recent state-
or region-specific data, EPA also relied on queries from the 1997 Census of Agriculture database
4-15
-------
(Table 4.3.5-2) that were used for the draft ralemaking that included region- and subsector-level
information (USDA NASS, 1999b).
Table 4.3.5-1
Number of Layer Operations by EPA Size Class from the 1997
Census of Agriculture Database
Sector
Size Class (EPA AU) „ ,
Medium!
(300-499 AU/
30,000-49,999
head
776
Medium 2
500-749 AU/
.50,000-74,999
head
446
Medium 3
750-999 AU/
75,000-99,999
head
238
Large -1 and 2
AU/
>100,000
head
671
*
,
Total
Operations
2,131
Source: USDA NRCS, 2002.
EPA made the following assumptions to reorganize the data presented in Table
4.3.5-2 to match selected facility size classes (Table 4.3.5-3 presents the results of these
assumptions):
• Pullet operations are located near and provide birds to laying operations.
Pullet operations >180,000 can be split into 180,000-600,000 and
>600,000 size classes using the proportion of layer operations (i.e.,
2377(237+89));
National pullet operations can be split into regions using the proportion of
layer operations in that region for each size class; and
• Other pullet size classes can be resized to the selected size classes by
assuming a uniform distribution of operations within each size class.
The number of wet layer operations is computed from the layer operations in Table
4.3.5-3 assuming 60 percent of the South and Central regions and 5 percent each of the other
three regions use wet layer systems (USDA APHIS, 2000). Applying these percentages to Table
4.3.5-3 results in 349.4 wet layer operations with more than 30,000 head (see Table 4.3.5-4).
4-16
-------
Table 4.3.5-2
Number of Layer Operations by Size Class and Region from 1997 Census
of Agriculture Database
;IRegion
30;ppO-62j500
v-.^-;;.;;;i-.Size.CIass(head)v ,. -- ; •>L-J.:.V,V> -;-•/_,,- •;
62,500-180,000
ISOjOOOifiOOjOOO
>6W,QO&
; Total
Operations
Layer and Layer/Pullet Operations
Central
Mid-Atlantic
Midwest
Pacific
South
Total
76
150
123
38
208
595
41
, 133
182
66
90 .<,.-
. 512
28
48
78
39
44
237
9
15
39
17
9
89
154
346
422
160
351
Pullet Operations
i- *'"'•"•• -T ,' : '
National
30,000-100,000
516
100,000-180,000
61
>180,000
'
NA = Not available.
Total
Operations
Table 4.3.5-3
Reorganized Layer and Pullet Operation Counts
Region
Layer Operations
Mid-Atlantic
Pacific
South
Total
Pullet Operations
Mid-Atlantic
Midwest
Pacific .
South
Total
-•• .-••:'•• • ,: •' •-. , Size Class (head) , i -'•:--
30,000r
49,999
50,000-
74,999
75,000-
99,999
100,000-
599,999
47
92
76
23
128
366
34
72
67
22
90
283
9
28
39
14
19
109
56
139
202
84
105
586
19
37
31
9
52
148
15
33
32
11
39
128
6
19
26
9
13
72
22
66
92
35
46
261
>600,000 ?
9
15
39
17
9
89
1
2
5
2
1
Total
Operations
154
346
422
160
351
1,433
63
157
185,
66
150
4-17
-------
Table 4.3.5-4
Reorganized Distribution of Dry Layer, Wet Layer,
and Pullet Operations by Region
r
Region
" IT Size Class (head) ~
30,000-
49,999
50,000-
74,999 "
75,000-
99,999
100,000-
599,999
5==3===2==525S==I
>600,000
JTJry Layer Operations , — — r
Central
vlid-Atl antic
Midwest
Pacific
South
Total
18.7
87.7
71.9
222
51.2
251.7
13.4
68.2
63.3
20.6
35.8
201.4
3.5
26.9
36.8
13.3
7.7
88.2
22.4
131.6
191.8
79.7
42.1
467.7
3.6
14.3
37.1
16.2
3.6
74.7
Wet Layer Operations , — — ,
Central
Mid-Atlantic
Midwest
Pacific
South
Total
Pullet Operations
Central
Mid-Atlantic
Midwest
Pacific
South
Total
All Operations
28.1
4.6
3.8
1.2
76.8
114.4
18.9
37.2
30.5
9.4
51.6
147.7
513.8
=====
20.2
3.6
3.3
1.1 '
53.7
81.9
5.2
1.4
1.9
0.7
11.5
20.8
33.5
6.9
10.1
4.2
63.2
117.9
14.7
32.6
31.8
10.5
38.6
128.2
411.5
i===
5.7-
18.6
25.5
9.2
12.6
71.7 „ .
180.6
================
22.2
66.1
92.1
34.8
46.3 .
.. 261.4
847.0
=====
5.4
0.8
2.0
0.9
5.4
14.4
1.2
2.0
5.3
2.3
1.2
12.0
101.0
=====
Total
Operations
61.6
400.9
152.0
140.4
1,083.6
- 11
i — —I
92.4 I]
17.3
21.1
8.0
210.6
349.4
1
62.6 1
156.5
185.2
66.3
150.3
621.0
2,054.0 J
4-18
-------
The USDA NRCS (2002) analysis (Table 4.3.5-1) did not divide the >1,000 AU
size class into the two size classes EPA uses in the modeling exercise. EPA maintained the facility
count from the original queries (USDA MASS, 1999b) for the largest operations with >600,000
head (i.e., 101 total operations with >600,000 head). For the remaining size classes, EPA used
the proportion of each operation typeje.g., dry layer, wet layer, pullets) using the facility count
from Table 4.3.5-4 (and repeated in the top half of Table 43.5-5) to disaggregate the data
provided in Table 4.3.5-1 . For example, the number of dry layers forjthe smallest size class is
equal to (251.7/513.8) x 776.0, or 380.1. •- - r • - - .........
Reorganized Distribution jrf Dry Lager, Wet Layer, and Pullet Operations
'f. r * %
Sector
, SizeClass (head)
30,000-
49,999
50,000-
- 74^99
75,000-
99^999
100,000-
-599,999
>600,000
Total
Operations
Facility Count using USDA NASS (1999c)
Dry Layers
Wet Layers
Pullets
Total
252
114
,148
514
201
82
128
412
88
' 21
72
181
468
118
261
847
75
14
12
101
' 1,084
349
621
•: 2,054
Facility Count using USDA NRCS (2002)
Dry Layers
Wet Layers
Pullets
Total
380
; 173 .
223
776
218
-, , 89
139
446
116
. 27
95
238
315
79
176
570
75
14
12
101
1,104
383
644
2 131
The facility counts using USDA NRCS (2002) data from Table 4.3.5-5 were
further disaggregated by region using the data in Table 4.3.5-4. Wet layer operations greater than
30,000 head were aggregated into one size class while dry layer and pullet operations were
combined by region and size class. Wet layer operations greater than 30,000 head were combined
since there are relatively few operations and potential issues related to disclosure precluded
further resolution. Pullets are housed in cages similar to layers, or on bedded floors such as
4-19
-------
broilers and turkeys. Therefore no separate model was developed for pullets. Though there are
many pullet farms located apart from the laying farms or broiler breeder farms, the production and
manure management at these operations is very similar to broiler and caged layer operations.
Therefore no separate model was developed for pullet farms. The results of these steps are
presented in Table 4.3.5-6. For example, the number of dry layers in the smallest Midwest size
class is (71.9/251.7) x 380.1 (for dry layers) plus (30.5/147.7) x 223.0 (for pullets) for a total of
154.7 operations. In addition, another 800 wet layer operations with 9,000-29,999 head were
included in Hie evaluation since their manure is handled in a wet form and the threshold for being-
a CAFO is lower than for dry manure management systems. The number of wet layer Operations
with 9,000-29,999 head was estimated as approximately equal to 7,300 operations x 0.73 x 0.15,
where 7,300 is the approximate number of operations in the South region with fewer than 3 0,000
head (USDA NASS, 1999b), 0.73- is the fraction of operations in the size class of 9,~000-29,999
relative to <30,000, and 0.15 is the fraction of these operations that use wet-manure-handling
systems.
In order to evaluate the impact of including smaller operations, the smallest dry
layer size class was expanded to include operations from 25,000-49,999. To account for the size
interval increasing by 25 percent, 25 percent more operations were added to the smallest size
class. Also, the division between the third and fourth dry layer size class was changed from
100,000 to 82,000. To account for this size class change, 72 percent of the operations from the
third size class were moved to the fourth size class. Seventy-two percent was selected because
that represents the size class interval change (e.g., 75,000-99,999 versus 75,000-81,999). Table
4.3.5-7 presents the estimated number of facilities by sector, size class, and region. Table 4.3.5-8
presents the final number of facilities by sector, size class, and modeled region, which distributes
the remaining dry layer operations from the Central, Mid-Atlantic, and Pacific regions evenly to
the Midwest and South regions. These operations use total confinement housing, and do not need
storage for feedlot runoff. Therefore, they are not subject to climate variations that result in
variable process waste water. All wet layer operations are modeled as the Southern region, which
accounts 65 percent of all wet layer operations.
4-20
-------
Table 4.3.5-6
Intermediate Layer Operation Counts by Sector, Size Class, and Region
=======
' Region
Wet Layers
Central
Mid-Atlantic
Midwest
South
Total
Region
Dry Layers
Central
Mid-Atlantic
Midwest
Pacific
Total
NA - Not applicable.
=====
NA *
„
NA - ' -
NA
NA
NA '
NA
NA
===========================—
Size Class (head)
NA
9,000- (
„,. 29,999^ „
>30,000
NA'
NA
NA
NA
NA .
NA
NA
196
32
27
8
537
800
99
18
21
8
237
383
Size Class (head)'
30,000-
49,999
50,000-
74,999
75,000-
81,999
82,000-,
599,999
57
189.
155
48
155
603
=====
31
109
103
34,
81
357
===
12
60
82
30
27
211
===£:
30
133"
191
77
60
491
- — '" '"_" '
NA
NA
NA
NA
NA
NA
>600,000
5
16
42
18
5
87
=====
==
Total
Operations
295
50
47
16
774
1,183
Total
Operations
. 134
507
573
207
327
1,748
=====
4-21
-------
Table 4.3.5-7
Final Layer Operation Counts by Sector, Size Class, and Region
i .1 i,l__JU L ^_,L'^-- -!-J- -'!' ' ' ""^g
Region
Wet Layers
Central
Mid-Atlantic
Midwest
Pacific
South
Region
Dry Layers' ' 1T|
Central i
Mid-Atlantic
Midwest
Pacific >
South-'-
Total
-...ill .,.._ ly^.n-— .i-.ll.i —
" ' Size Class (head)
NA
NA
NA
NA
NA
NA
" ' NA
'25,000-
49,999
' SD \ • , -
'71
236 . „
193
. . 60 - -
,.,...194,—
754
=========
NA ••'•
, 9^000-
29,999
>30,000
NA
NA
NA
NA '"'"'•
NA
NA
•• .. - ••••-•••••;§
50,000-
74^99
196
32
27
< ••> -g '
537
800
75,000-
81^99
99
18
21
8
237
383
82,000-
599,999
L'"1'-1..
31 J ,,
109,, ..;
103
HA
81 • —
357 - :
==============
3
....... 17, ,
._.. 23
._ „. - 8, . -
...... 8
59
'
39
1,76
250 -..
. 99
79
642-
=======
=====
-&&
NA
NA
NA
NA
NA
NA
>600,000
5
16 .
. : 42
. .- 18 ••-
5
87
=====
^^=^±K«iiiii-«*—
•X -Total. .
Operations
2.95
50
47
16
774
1,183
'.. • "Total; i;
Openationsi
148
.. , 554
_612
. 219
366
1,899
-=
NA-Not applicable.
4-22
-------
Table 4.3.5-8
w
Final Layer Operation Counts by Sector, Size Class, and Modeled Region
Region
Wet Layers
South
y_ Region
Dry Layers
Midwest
South
Total
Size Class (head)
NA *
~~r$£-""f
9,000- "
29,999
>30,000
NA
-
NA
NA
800
383
NA
„ ,', _,l :' Size Class (Head)
25,000-
49,999 ,
50,000-
"74,999" "
75,000-
81>99
82,000-
599,999
>600,000
377
377
754
190
167
357
37
22
59
407
235
642
62
25
87
Total
Operations
1,183
-Total,
Operations
1,073
827
1 899
IN/\ - JNOI applicable.
Not all medium operations are expected to be CAFOs under the rule. The percentage of medium
operations EPA estimates will be CAFOs is presented in Tables 4.3.5-9 and 4.3.5-10 (See
Preamble Section 4 and 40 CFR part 122.23).
Table 4.3.5-9
Percentage of Layer Operations That Are Expected to Be_CAFOs
Region
Central
Mid-Atlantic
Midwest
Pacific
South
.;,,/;;,, .:;....- v^'u • -Size-Class^ ^ •;;••••.; ^V;->:
Medium 1 :
3
3
3
3
3
Medium 2 ;
3
3
3
3
3
Mediums
3
3
3
3
3
.,-'Large,d-';;
100
100
100
100
100
4-23
-------
Table 4.3.5-10
Percentage of Dry Layer Operations That Are Expected to Be CAFOs
Region
Central
Mid-Atlantic -
Midwest
Pacific
South
- .••.'.-.•: .Size-Class • • • : ••
"All Medium
. 2
2
2
5
- 2
All Large :
100
100
100
100
100
Turkeys
Table 4.3.5-11 presents the total number of turkey operations using the 1997
Census of Agriculture database (USDA NRCS, 2002). Lacking state- or region-specific data,
EPA also relied on queries from the 1997 Census of Agriculture database (Table 4.3.5-12) that
were used for the draft rulemaking that included region-level information (USDA MASS, 1999b).
Table 4.3.5-11
Number of Turkey Operations by Size Class from 1997 Census of
Agriculture Database
Animal Type
Size Class (EPA AU)
Medium 1
300-500 AU/
16,500-27,499
head
Medium 2
500-750 AU/
27,500-41,249
head
478
Medium 3
750-1000 AU/
41,250-54,999
head
262
Large!
>1,OOOAU/
>55jOOO head
388
, •;' Total .V
Operations ,
2,003
Source: USDA NRCS, 2002.
4-24
-------
Table 4,3.5-12
Number of Turkey Operations by Size Class and Region from 1997 Census of
Agriculture Database
Source: USDANASS, 19991^-
EPA made the following assumptions to reorganizelhe data presented in Table 4.3.5-13 to match
the selected facility size classes (Table 4.3.5-14 presents the results of these assumptions):
! ~ .' : T ;•
.-*.... 'Large turkey operations use total confinement housing and generally do -
not store litter uncovered. Therefore climate does not play a. role in
manure and process wastewater generation.
More than 75 percent of turkey operations are located in the Mid-Atlantic
and Midwest regions, i.e., the key regions. Separate model farms were
developed for the two key regions to account for .differences in facility _
operation (e.g., crop rotations and BMP implementation).
• . Operations in the combined Pacific and South region were split based on
the total number of turkey -operations reported in the 1997 Census of
Agriculture state summaries. (Approximately 39 percent of the combined
Pacific and South region were assigned to the Pacific Region.)
Turkey size classes can be resized to the current size classes by assuming a
uniform distribution of operations within each size class. "
The facility counts -in- Table 4.3.5-11 can be disaggregated using the data provided
in Table 4.3.5-13 (see Table 4.3.5-14). For example, EPA calculated the number of Central
region operations in the smallest size class as (27,0/683.0) x 875, or 34.6 operations. Table
4.3.5-15 presents the final number of facilities by size class and modeled region, which were
4-25
-------
distributed from the Central, Pacific and South regions evenly to the Mid-Atlantic and Midwest
regions.
Table 4.3.5-13
Reorganized Turkey Operation Counts
Region
Size Class (head)
16,500-
27,499
27,500-
41,249"
41,250-
54,999
2:55,000
Total Operations
Central
27
30
16
34
107
Mid-Atlantic
299
322
119
83
823
Midwest
247
267
101
142
756
Pacific
43
49
27
43
162
South
68
76
Total
683
744
305
Table 4.3.5-14
Final Turkey Operation Counts by Size Class and Region
—
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Total
•."V .., Size Class (head) ;':•/=• : - ••
16,500-
27,499
35
382
316
56
87
875
27,500-
41^249 ";
19
207
. 171
31
49
478
' 4i,250-
; 54,999 ,
14
102
87
23
36
262
=====
^55,000
36
87
149
45
70
388
^ss^ssss^s^^^ssssss
Total Operations
103
779
723
155
242
2,003
4-26
-------
Table 4.3.5-15
Final Turkey Operation Counts by Size Class and Modeled Region
;Xtf.v- 'Region
Mid-Atlantic
Midwest
Total
Size Class (head) ^
16,500-
27,m 7
471
404
875
27,500-
" 41,249
257--
.221
478
41,250-
54,999
139
123
262-
"^55,000
163
. 225
388
Total Operations
1,030
973 .
2-003
Not all medium'operations are expected to be CAFOs under the rule. The percentage of medium
operations EPA estimates will be CAFOs is presented in Table 4.3.5-16 (See Preamble Section 4
and 40 CFR part 122.23). ..;,,.
Table 4.3.5-16
1 ' i ••— i
Percentage of Turkey Operations That Are Expected to Be CAFOs-
Region
Central
Mid-Atlantic
Midwest
Pacific
South
/:;v:v,::.i:«ize*Cias)Sv,.';;Cv-;;i
AM Medium
.2
2
2
2
5
.-.•,;;pl 100,000 head, 50,000-99,999 head, and 30,000-
49,999 head.
4-27
-------
Table 4.3.5-17
Number of Broiler Operations as Provided by USDA NRCS (2002) Based on
Analyses of 1997 Census of Agriculture Database
======
Location
AL
AR
•
GA
K.T, TN, VA, WV
MD.DE
MS
NC.SC
OK, MO, KS
TX,LA
Other
T and Availability
Category
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
'-.-'. ; Operation Size and Nutrient Basis
2:100,000
N ;
d
98
268
d
69
260
d
169
382
d
58
187
d
62
38
d
72
230
d
105
177
d
26
124
d
53
231
d
113
100
,:P. ••'.
d
98
274
d
69
263
d
169
387
d
58
201
d
62
73
d
72
230
d
105
198-
d
26
126
d
53
231
d
113
104
50,000-99,999
,• N, -••.-.
34
227
666
58
155
797
17
319 •
494
34
169
304
106
275
146
10
172
437
61
287
394
19
49
248
23
117
312
41
162
190
};• ,?•:.;•/,
15
227
685
49
155
806
6
319
505
17
169
321
31
275
221
8
172
439
12
287
44-3
12
49
255
21
117
314
11
162
220
30,000-49,999
-N;,: .,
39
217
412
104
226
672
14
194
250
23
129
149
103
294
107
14
70
143
59
290
292
30
32
171
9
41
86
45
112
99
P
32
217
419
93
226
683
10
194
254
15
129
157
38
294
172
14
70
143
19
290
332
29
32
172
8
41
87
17
112
127
d - Data not disclosed.
4-28
-------
Land availability:
Location:
Nutrient basis: -
No excess (Category 1 farms with sufficient crop or
pasture land).
Excess, with acres (Category 2 farms with some
land, but not enough land to assimilate all manure
nutrients)..--.
Excess, no acres (Category 3 farms with none of the
24major crop, types identified by NRCS).
Ten states or groups of states.
j"
Applications are based on nitrogen (N) or "
_ phosphorus _(P) application rates.
For an example of the data contained in Table 4:3.5-17, in Alabama there are 98
facilities with more than 100,000 birds with none of the 24" major crop types identified by NRCS
for application of animal wastes. There are 268 operations and 274 operations with 100,000 or
more birds with some land in Alabama, but not enough land to assimilate all manure nutrients
using nitrogen-based and phosphorus-based application rates, respectively. An undisclosed
number of facilities have enough land (i.e.'rno excess manure). 'Based on additional USDA NRCS
(2002) information, there are a total of 2,945 operations with 100,000 or more head, 6,323
operations with 50,000-99,999 head, and 4,426 operations with 30,000-49,999 head within the
United States. Thus, by comparison to Table 4.3.5-17, EPA concluded that 123 operations with
100,000 or more head do not have excess manure using nitrogen-based application rates and 33
operations do not have excess manure using phosphorus-based application rates. USDA NRCS
(2002) also computed from the 1997 Census of Agriculture that there are a total of 598 broiler
operations with 180,000 or more birds and 1,034 broiler operations with 125,000-179,999 birds.
Based on these data, EPA adjusted the size classes to the following: 37,500-
49,999, 50,000-74,999, 75,000-124,999, 125,000-179,999, and ^180,000. Thus, using a uniform
distribution, EPA eliminated 37.5 percent of the 4,426 operations with 30,000-49,999 head from
4-29
-------
consideration, leaving 2,766 operations in the smallest size class and 12,034 total broiler
operations. Based on the above information, the data in Table 4.3.5-17 were modified to account
for the undisclosed operations and the modified size classes, and were further disaggregated to
• . , . ••" ^ ,
match the five size classes selected by EPA for modeling. Tables 4.3.5-18 and. 4.3.5-19 present
the results of these calculations for nitrogen- and phosphorus-based application rates,
respectively.
Because thejQcgtion groupings in Tables 4.3.5-18 .and. 4.3.5-19 do npt match the
regions chosen by EPA for modeling, it was necessary to disaggregate the data in Tables 4.3.5-18
and 4.3.5-19 to the state level. The data in Tables 4.3.5-18 and 4,3.5-19 were disaggregated by
using the number of operations with 200,000-499,999 broilers sold or 500,00,0 or more broilers
sold as reported in the 1997 Census of Agriculture state summaries. The number of operations
with 500,000 or more broilers sold was used for the larger three class sizes. State-disaggregated
data were then recombined into regions chosen by EPA for modeling. The results of these
calculations are presented in Tables 4.3.5-20 and 4.3.5-21. .Approximately 87 percent of all
broiler operations with more than 30,000 bird spot capacity were located in the South and Mid-
Atlantic regions in 1997 (USDA NASS, 1999b). These two regions were selected as the key
regions. Since climate is not a major factor in. estimating costs at broiler operations (which have
total confinement buildings and generally have covered manure storage), total birds from the
Midwest, Central and Pacific regions were divided equally among the South and Mid-Atlantic
regions for modeling purposes (see Tables 4.3.5-22 and 4.3.5-23).
4-30
-------
Table 4.3.5-18
Intermediate Number of Broiler Operations Based on Location, Land
Availability Category, Operation Size for Nitrogen-Based
Application of Manure
Location
AL
AR
GA
KT, TN, VA, WV
MD,DE
MS
NC,SC
OK, MO, KS
TX.LA
Other
Land Availability
Category '
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres :
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres v
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
Total
180,000+
4
20
54
. • - 1 -
14
53
1
34
78
4
12
38
8
13
8
1
15
47
5
.21
36.
1
5
25
0
11
47
1
23
20
598
125,000-
179,999
7
34
94
1
24 •
91
2
59
134
7
20
66
14
22
13
2
25
81
8
37
62 -.
2
9
44
0
19
81
1
40
35
1 034
75,000-
124,999
,20
133
389
34
91
466
10
186
289
20
99
178
62
161
85
6
101
255
36
168
230
11
29
145
13
68
182
24
95
111
3 693
50,000-
74,999
21 ,.
142
415
36
97
497
11
199
308
21
105
190
66
172
91
6
107
273
38
179
246
12
31
155
14
73
195
26
101
119
3 943
37,750-
49,999
, .24
136
258
65
141
420
9
121
156
14
81
93
64
184
67
9
44
89
37
181
183
19
20
107
6
26
54
28
70
62
2 766
4-31
-------
Table 4.3.5-19
Intermediate Number of Broiler Operations Based on Location, Land
Availability Category, Operation Size for Phosphorus-Based
Application of Manure
Location
AL
AR
GA
KT,TN,VA,WV
MD, DE
MS
NC.SC
OK, MO, KS
TX,LA
Other
Land Availability
Category
No excess
Excess, no acres
Excess, with acres
No excess "-••-- ' •
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres-
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
iso;o6(H-
3
20 ,
56
0
14
53
0
34
79
1
. 12
41
1
13
15
1
15
47
0
21
40
1
5
26
0
11
47
0
23
21
598
179,999
5
34
96
0
' 24
92
,0
59
136
2 -
20
71
2
22
26
2
25
81
0
37
70
. 1
9
44
0
19
81
0
40
37
1,034
124,999
9
133
400
29
91
471
4
186
295
10
99
188
18
161
129
5
101
256
7
168
259
7
29
149
12
68
183
6
95
129
3,693
'74,999' V-"
9
142
427
31
97
503
4
199
315
11
105
200
19
172
138
5
107
274
8
179
276
8
31
159
13
73
196
7
101
137
3,943
49,999
20
136
262
. 58
141
427
6
121
159
9
81
98
24
184
108
9
44
89
12
181
208
18
20
108
5
26
54
11
70
79
2,766 .
4-32
-------
Tablp 4.3.5-20
Final Number of Broiler Operations Based on Region, Land Availability
Category, Operation Size for Nitrogen-Based Application of Manure
' Region
Central
Mid-Atlantic
Midwest .
.Pacific
South
Land Availability
Category
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres.
Excess, with acres '
No excess
Excess, no acres
Excess, with acres
No excess
Total
180,000+
11
48
1
51
84
16
8
13
1
3
3
0
95
258
7
598
125,000-
179,999
19
84
2
88
145
28
13
22
1
5
4
0
164
446
13
1,034
75,000- ,
124,999
65
222
17
438
502
121
34
70
10
12
14
3
580
1,521
85
3,693
50,000-
74,999
66
199
15
422
475
119
36
125
12
39
45
10
642
1,643
96
3,943
.37,750-
49,999
26
75
10
405
300
110
24
83
17
27
24
11
521
1,007
127
2766
4-33
-------
Table 4.3.5-21
Final Number of Broiler Operations Based on Region, Land Availability
Category, Operation Size for Phosphorus-Based Application of Manure
Region
Central •••
Mid-Atlantic
Midwest
Pacific
South
LandAvailabffity
Category • r "r"
Excess, no acres
Excess, with acres
No excess -- —
Excess, no acres
Excess, with acres ...
No excess
Excess, no acres
Excess, with acres —
No excess
Excess, no acres "
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
180,000*
11
49 . ..
1 ...
- SI'
' 98
2
8
.13
0
' ,.'3
3
0
95
262
4
~ 598 ""
125,000-
179,999
19
,84.
-• -1
88'~
170
4
13
......22.. .
0
,5
5
. 0
...,164
452-
6-
1,034
75,000-
1^4#99;
65
.. 22.6 ,._
---13
438
587
36.
34
76 ...
..4 '
12
16
1
. 580
. 1,554
52
3,693
V7;4,999"-:. '
66
.. ,2Q1_
... . .13 ;
422™™
558
37
.,,36_ ,„
130 .,
6 ' " ~
39
53
3
642
1,683
56
3,943
49,999
26
., J6
10 -
•--405 '
366
43
, .24
.86
14
' 27
30
4
521
1,033
1.01
2,766
4-34
-------
Table, 4.3.5-22 >
Final Number of Broiler Operations Based on Modeled Region, Land
Availability Category, Operation Size for Mtrogen-Based
Application of Manure
Region
Mid-Atlantic
South
Land Availability
Category -* ' „
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres i
No excess
Total
180,000+
62
116
17
106
290
8
598
125,000-
179,999
107
200
29
183
r501
14
1,034
75,000-
124,995
494
655
136
635
. T,674
100
3,693
50,000-
74,999
492
660
137
713 ' '
l,-827:;
114
3,943
37,750-,
49,999
444
391
129
560
1,097- ; .
146
2 766
Table 4.3.5-23
Final Number of Broiler Operations Based on Modeled Region, Land
Availability Category, Operation Size for Phosphorus-Based Application
of Manure
Region }
Mid-Atlantic
South
Land Availability
• -Category. • .. '•••'•"'•}•• :
Excess, no acres.
Excess, with acres ' :
No excess
Excess, no acres
Excess, with acres
No excess
Total
180,000+
62
130
3
106
294
4
. 598
125,000-
179,999 „
107
225
5
183
508
7
1,034
75,000-
124,99,9
494
746
45
635
1,713
61
3,693
50,000-
-74,999-
492
750
47
713
1,875
66
3,943
37,750-
49,999 i
444
462
57
560
1,129
115
2766
Not all .medium operations are expected to be CAFOs under the rule. The percentage of medium
operations EPA estimates will be CAFOs is presented in Table 4.3.5-24 (See Preamble Section 4 '
and 40 CFR part 122.23).
4-35
-------
Table 4.3.5-24
Percentage of Broiler Operations That Are Expected to Be CAFOs
Region
Central _ ,
Mid-Atlantic
Midwest
Pacific
South
. . Size Class • . .•••',
AU Medium
.-...5
,,5,
5
5
5
All Large; -
100 .
100 .
100 --
100
100
4.3.6
Farm Counts - Swine Operations
USD A NRCS (2002) .provided information to EPA on the number of swine
operations based on the following classifications as shown in Table 4.3.6-1:
Operation size:
Land availability:
Location:
Nutrient basis:
>2,500 head, 1,250-2,499 head, and 750-1,249
head.
No excess (Category 1 farms with sufficient crop or
pasture land). . -
Excess, with acres (Category 2 farms with some
land, but not enough land to assimilate all manure
nutrients).
Excess, no acres (Category 3 farms with none of the
24 major crop types identified by NRCS).
Eleven states or groups of states.
Applications are based on nitrogen (N) or
phosphorus (P) application rates.
4-36
-------
As an example of the data contained in Table 4.3.6-1, in Illinois there are 72 "
facilities with more than 2,500 head with none of the 24 major crop types identified by NRCS for
application of animal wastes. There are 34 operations with 2,500 or more head that have some
land in Illinois. However, these operations do not have enough land to assimilate all of the manure
nutrients using nitrogen-based application rates. There are 184 Illinois operations with 2,500 or
more head that have enough land to assimilate all manure nutrients using nitrogen based
application rates. Based on USDA NRCS (2002) analysis of the 1997 Census of Agriculture
data, there are a total of 3,924 operations with 2,500 or more head, 1,507 operations with 1,875-
2,499 head, 2,840 operations with 1,250-1,874 head, and 5,554 operations with 750-1,249 head
within the United States. '
•»)•'.»
Based on these data, EPA adjusted these size classes to the following: 750-1,249,
1,250-1,874, 1,875-2,499, 2,500-4,999, and >5,000. Using data provided by USDA NRCS
(2002), EPA placed 65.33 percent of the operations in the 1,250-2,499 size class into the 1,250-
1,874 size class. Based on data from USDA NASS (1999b), EPA placed 41.8 percent of the
operations in the >2,500 size class into the >5,000 size class. Thus, the information in Table
4.3.6-1 was reaggregated to match the five size classes selected by EPA for modeling. Tables
4.3.6-2 and 4.3.6-3 present the results of these calculations for nitrogen- and phosphorus-based
application rates, respectively.
EPA then imputed the data in Table 4.3.6-2 and Table 4.3.6-3 to the state level by
using the number of operations with 1,000 or more hogs and pigs sold as reported in the 1997
Census of Agriculture state summaries. State-disaggregated data were then recombined into
regions (see Tables 4.3.6-4 and 4.3.6-5). Facilities from the South, Pacific, and Central regions
were divided equally among the Mid-Atlantic and Midwest regions for modeling the three smaller
size classes and combined into the Central region for the larger two size classes for modeling
purposes (see Tables 4.3.6-6 and 4.3.6-7).
4-37
-------
Table 4.3.6-1
Number of Swine Operations as Provided by USDA NRCS (2002) Based on
Analyses of 1997 Census of Agriculture Database
Location
AR, KS, OK
1L
IN
IA
MI.WI
MN
MO
NC
NE
OH
Other
Land Availability
: Category
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
£2,500
, N- •-
52
66
113
184
72
34
179
68
35
411
211
120
57
31
19
225
152
50
54
17
59
194 •
185
630
40
81
32
45
23
12
184
132
157
-'•fc.'. :•:•••
21
66
144
95
72
123
107
68
107
164
211
367
25
31
51
97
152
178
32
17
81
15
185
809
15
81
57
23
23
34
87
132
254
1,250-2*499
;,N-:
76
36
78
357
45
31
254
53
29
1,155
183
89
97
30
19
386
83
28
104
18
48
83
71
157
164
49
29
98
33
17
244
99
104
P
50
36
104
283
45
105
205
53
78
796
183
448
65
30
. 51
272
83
142
87
18
65
23
71
217
141
49
52
61
33
54
145
99
203
750-1^49 1
; N • -.
101
.22
40
528
39
21
387
50
36
1,587
235
51
169
29
8
523
69
28
203
25
33
56
33
45
279
82
29
202
31
29
404
102
78
•>iv •:•
80
22
61
472
39
77
346
50
77
1,346
235
.292
136
29
41
430
69
121
183
25
53
21
33
80
245
82
63
154
31
77
289
102
193
4-38
-------
Table4.3.6-2
Intermediate Number of Swine Operations Based on Location, Land
Availability Category, Operation Size for Nitrogen-Based Application
of Manure
Location
AR, KS, OK
IL
IN
IO
MI,WI
MN
MO
NC
NE ;
OH
Other
Land Availability
Category
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
Total
•. Size Class
5,000+
22
28
47
77
--.- 30 .
14
75
28
15
172
88
50
24
13
8
94
64
21
23
7
25
81
77
263
17
34
13
19
10
5
77
55
66
1,639
2,500-
4,999
30
38
66
107
- 42
20
104
40
20
239
123
70
33
18
11
131
89
29
31
10
34
113
108
367
23
47
19
26
13
7
107
77
91
2,285
1,875-
2,499
26
13
27
124
16
11
88
18
10
400
63
31
34
10
7
134
29
10
36
6
17
29
25
54
57
17
10
34
11
6
85
34
36
1 507
1,250-
1,874
50
24
51
233
29
20
166
35
19
755
120
58
63
20
12
252
54
18
68
12
31
54
46
103
107
32
19
64
22
11
159
65
68
2 840
750-1,249
101
22
40
528
39
21
387
50
36
1,587
235
51
169
29
8
523
69
28
203
25
33
56
33
45
279
82
29
202
31
29
404
102
78
5 554
4-39
-------
Table 4.3.6-3
Intermediate Number of Swine Operations Based on Location, Land
Availability Category, Operation Size for Phosphorus-Based Application
of Manure
Location
AR,KS,OK
IL
t
IN
,
10
MI.WI
MN
MO
NC
NE
OH
Other
Land Availability ;
Category
No excess
Excess, no acres
Excess, with acres
No excess :. '
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
5,000+
9
28
60
40
30
51
45
28
45
69
88
153
10
13
21
41
. 64
74
13
7
34
6
77
338
6
34
24
10
10
14
36
55
106
1,639
2,500-
4,999
. 12
38
84
55
42
72
62
40
62
96
123
214
15
18
30
57
89
104
19
10
47
9
108
471
9
47
33
13
13
20
51
77
148
2,285
1,875-
2,499
17
13
36
98
16
36
71
18
27
276
63
155
23
10
18
94
29
49
30
6
23
8
25
75
49
17
18
21
11
19
50
34
70
1,507
1,874
33 .
24
68
185
29
69
134
35
51
520
120
293
43
20
33
178
54
93
57
12
43
15
46
142
92
32
34
40
22
35
95
65
133
2,840
750-1,249
, 80
22
61
472
39
77
346
50 '
77
1,346
235
292
136
29
41
430
69
121
183
25
53
21
33
80
245
82
63
154
31
77
289
102
193
5,554
4-40
-------
Table 4.3.6-4
Final Number of Swine Operations Based on Region, Land Availability
Category, Operation Size for Nitrogen-Based Application of Manure
; f Region
Central
Mid-Atlantic
Midwest • ~ ••
Pacific
South
Land Availability
Category ~"
Excess, no acres
Excess, with acres
No excess
Excess, no acres
.'Excess, with acres
No excess
Excess, no acres
Excess, with.acres
No excess
Excess, no; acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Total
'5,000*
10
14
11
102
292
115
..-_ ,300
188
528
2
2
2
21
30
23
1,639
2,500-
4,999
- 13
19
15
142
408
161
418
263
736
2
3
3
29
42
32
2,285
1,875-
^499 -
5
8
12
40 ,
71
67
185
122
939
1
1
3
11
17
26
1,507
1,250-
1,874
10
15 •
23
75
133
125
349
229
1,770
2
2
5
21
32
49
750-1,249
13
14
54
79
80
236
595
212
4,022
3
2
12
28
30
115
4-41
-------
Table 4.3.6-5
Final Number of Swine Operations Based on Region, Land Availability
Category* Operation Size for Phosphorus-Based Application of Manure
Region
Central
Mid-Atlantic
.. .__,, „ ,._,__
Midwest
Pacific — —
South
Land Availability
Category •- :
Excess, no acres
Excess, with acres
No excess, ...
Excess, no acres •-- — •-
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
No excess ~.,
Excess, no acres
Excess, with acres
No excess
5,000-H
10 "
20
__,. J.5 .,
102-
—-38S""
*-~™23
300
470
,, 246
-2 •
3
1
21
43
10
1,639
2,500-
4$999
'13
27
... 7
142
537
31 "
418
655
343 .. ,
« - 0
-£•
5
' "2
29
60
14
2,285
2,49? 1 -
5
12
.8
40
107
30
185
379
.682
1-
2
2
11
27
16
1,507
;:;vl»874
10
23
.14
75
^01
57
349
713
1,286
... —9 • •
4
3
21
51
30
2,840
750-1,249
13
- 28 •-.
40 .
_- 79
166
150
595
876
3,419
•-•3-
6
9
28
60
85
5,554
4-42
-------
Table 4.3.6-6
Final Number of Swine Operations Based on Modeled Region, Land
Availability Category, Operation Size for Nitrogen-Based Application
of Manure ,
''jt: qvRegion
Central
Mid-Atlantic
Midwest
•
1 Total _
1
Land Availability
Category
Excess, no acres
Excess, with acres
No excess
Excess, no acres •
Excess, with acres
No excess , ;
Excess, no acres
Excess, with- acres
No excess
'
5,000+
32
46
36
102
292 ,
-.11.5
300
188
528
1,639
2,500-
.4,999
45
64
50
142
-408
161
..418
263
736
2,285
1,875-
2,499
0
... Q
0
49
84
87
194
135
959
1,507
1,250-
1,874
, 0
0
0
92
157- -
164
366
254
1,808
2.840
=====
750-1,249
0
0
--o
100
103
327
617
295
4,113
5,554
Table 4.3.6-7
Final Number of Swine Operations Based on Modeled Region, Land
Availability Category, Operation Size for Phosphorus-Based Application
of Manure
; V Region
Central
Mid-Atlantic
Midwest
1 Total
11
Land Availability
Category
Excess, no acres
Excess, with acres
No excess
Excess, no acres
Excess, with acres
Excess, no acres
Excess, with acres
No excess
=======
5^0047
32
66
16
102
385
23
300
470
246
1.639
2,500-,
4^999
45
92
22
142
537
31
418
655
343
2.285
==========
1^875-
2,499
0
0
0
• 49
127
43
194
399
695
1,507
============
1,250-
1,874
0
0
0
92
240
81
366
752
1,309
2.840
=========
750-1,249;
0
0
0
100
213
217
617
922
3,485
5.554
^^=asss
4-43
-------
While USDA NRCS (2002) provided information to estimate the number of
operations by region, size class, and land availability category, it did not provide data to estimate
the number of operations by operation type (i.e., farrow-to-fmish, grow-finish) or the number of
operations by manure storage_(i.e., pit storage, lagoon, evaporative lagoon). Using data provided
by USDA NASS (1999b), EPA estimated that 50.6,45.6, 40.7, and 35.0 percent of operations
with 2,500+, 1,875-2,499,1,250-1,874, and 750-1,249 head, respectively, were grow-finish
operations. Using data from USDA APHIS (2002), EPA estimated the following percentages of
swine operations that use pit storage:, 14.4 and 23.9 percent of medium and large farrow-to-finish
operations, respectively, and 26.3 and 37.5 percent of medium and large grow-finish operations,
respectively, in the Mid-Atlantic" region; and 5*9Hnd 56.4 percent of medium and large farrow-
to-finish operations, respectively, and 6717 and 70.7 of medium and large grow-finish operations,
respectively, in the Midwest region. All operations modeled in the Central region were assumed
to use evaporative lagoons. , . .„„__.,.,.....
Not all medium operations are expected to be CAFOs under the rule. The
percentage of medium operations EPA estimates will be CAFOs is presented in Table 4.3.6-8
(See Preamble Section 4 and 40 CFR part 122.23).
Table 4.3.6-8
Percentage of Swine Operations That Are Expected to Be CAFOs
Region
Central
Mid-Atlantic
Midwest
Pacific
Size Class
Medium 1
15
15
15
15
Medium 2
15
15
15
15
15
Medium3
15
15
15
15
15
Large!
100
100
100
100
100
4-44
-------
4.4
Average Head
• ,-,..> This section describes the methodology used to calculate average head in each size
group for each animal type.
4.4.1
Average Head - Beef Feedlots
Table 4.4.1 -1 presents the total number of fattened cattle at potential beef feedlot
CAFOs by size class, as estimated by USDA NRCS, using the 1997 Census of Agriculture data
(USDA NRCS, 2002).
Table 4.4.1-1
Number of Fattened Cattle at Potential CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
si Size Class .-.
Medium 1
Medium 2
Medium 3
Size Class
Large 1
Large 2
Number of Beef
Feedlots
1,466
801
415
Number of Beef
Feedlots
1,654"
421
Number Fattened Cattle
Based on 2.5
tumov«rs/year and .
1,000 pounds
251,015
204,850
147,322
Number of Fattened
Cattle Sold
4,347,000
18,442,000
Based on variable
turnovers and 877
pounds
541,742
442,109
317,951
Number On Site
(based on variable
turnovers)
10,902,500
3,041,250
Average Number of
.Fattened Cattle
370
552
766
Average Number'of
Fattened Cattle
1,839
25897
JNumber;Oi Large
Large 1 size class.
1 beet reedlots estimated by USDA/NASS. This estimate is used only to calculate the average head for the
To estimate average head at Medium beef feedlots, EPA first converted these
animal unit estimates back to sales estimated using the turnover of 2.5 beef cycles per year (ERG,
2002). Information collected by EPA from the National Cattlemen's Beef Association and the
USDA National Agricultural Statistics Service indicate that beef feedlots generally operate at less
than 100 percent capacity, and smaller feedlots tend to have less production cycles per year.
4-45
-------
Based on these data, EPA used production cycle estimates based on the size of operation to
recalculate head estimates from the sales data (ERG, 2002). EPA also recalculated the number of
beef cows based on a weight of 877 pounds, as shown in the equation below:
# Fattened CattlerottiHc8d = # Fattened CattleAu x
2.5
Weightxu
Tumoversize class Weightier c<>w
x
where:
# Fattened CattleAU
Tumbversizeaass
WeightAU'
WeightBeefCow. —
USDA's NRCS data for number of AU for a size
class
Estimated number of production cycles for a size
class""' '" %v --••••••-•
- -Weight of one animal unit (1,000 Ibs) -
»Average weight of beef cow (877 Ibs).
Next>_EPA calculated the average head per operation by dividing the number of fattened cattle'by
the number of operations. These average head are also presented in Table 4.3.1-1.
For example, USDA estimates that there are 204,850 animal units at Medium 2
operations. Multiplying this number by 2.5 turnovers and converting the weight basis to 877
pounds yields 583,951 cows. It is estimated that there are 1.32 production cycles at these
operations, which yields 442,109 cattle at 801 operations in the Medium 2 size class, which
results in an average head size of 552 fattened cattle at Medium 2 operations.
For large operations, the USDA/NRCS data does not provide the number of head
for both the Large 1 and Large 2 size classes. Instead, EPA used data from USDA/NASS to
estimate the average head at large operations. - ~
4.4.2
Average Head - Dairies
Table 4.4.2-1 presents the total number of milk cows at potential dairy CAFOs by
size class, as estimated by USDA's NRCS, using the 1997 Census of Agriculture data (USDA
NRCS, 2002). The estimates prepared by NRCS are presented as the number of animal units
4-46
-------
assuming a weight of 1,000 pounds per animal unit. EPA first converted these animal unit
estimates to the number of dairy cows based on a weight of 1,350 pounds, as shown in the
equation below:
where:
# Mature Dairy Cows™H^=# Mature Dairy COWSA
WeightAu
#Mature Dairy Cows
WeightAU
WeightDaiiyCattle
'AU
ity Cattle
USDA's NRCS data for number of farms
with milk cows for a size category
Weight of one animal unit (1,000 Ibs)
Average weight of dairy cow (1,350 Ibs).
Table 4.4.2-1
Number of Dairy Cows at Potential CAFOs by EPA Size Class
from the 1997 Census of Agriculture Database
• SizeClass
Medium 1
Medium 2
Medium 3
Large 1
Number of Dairies
3,805
1,372
603
1,450
Number of At)
• 1,285,821
787,492
488,283
2,798,343
Number of Dairy Cows
952,460
583,327
361,691
2,072,847
Average Number of
MsiturefDairyiGows
250
425
600
1,430
Next, EPA calculated the average head per operation by dividing the number of
dairy cows by the number of operations. These average head are also presented in Table 4.4.2-1.
For example, USDA estimates that there are 787,492 animal units at Medium 2
operations. Converting this number to dairy cows yields 583,327 cows. It is estimated that there
are 1,372 operations in the Medium 2 size class, which results in an average head size of 425
dairy cows at Medium 2 operations.
4-47
-------
# Mature Dairy Cowsxotai head = 787,492 x
1,000
1,350
4.4.3
# Mature Dairy CowsTotaihead = 583,327
583,327
# Mature Dairy COWSHead per farm =
i yj I £*
# Mature Dairy COWSHead per farm = 425
Average Head - Heifer Operations
The average size of heifer operations ranges from 50 head to 25,000 head and
varies geographically. The average size of a heifer operation located west of the Mississippi River
is 1,000 to 5,000 head, while the average size in the upper Midwest, Northeast, and South is 50
to 200 head. Nationally, the median size of a heifer operation is approximately 200 head (Cady
R., 2000). The average head for each Medium size class is calculated as the median of the size
class range, as shown in Table 4.4.3-1.. Using best professional judgement, EPA set the Large
size class equal to 1,500 head.
Table 4.4.3-1
Average Head for Heifer Model Farm
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Average Head
400
625
875
1,500
4.4.4
Average Head - Veal Operations
The average head of veal calves in each size class is based on discussions with the
American Veal Association and site visits (Crouch A., 1999). A veal confinement bam may hold
between 200 and 300 calves, and on average houses 270 calves. Most commonly, veal operations
have two bams. Therefore, the Medium 1 facilities were estimated to have two confinement
4-48
-------
barns with 200 calves per bam, Medium 2 facilities were estimated to have two barns with 270
calves in each bam, and Medium 3 facilities were estimated to have four barns with 270 calves in
each barn, as presented in Table 4.4.4-1. , ,
Table 4.4.4-1
Average Head for Veal Model Farm
Size Glass
Medium 1
Medium 2
Medium 3
Average Head , .'.-^
400
540
1,080
4.4.5
Source: ERG, 2000b.
Average Head - Poultry Operations
The calculation of average head for poultry operations includes separate •
calculations for layers, turkeys, broilers. Each of these is described hi detail in the following
discussion.
Layers
Table 4.4.5-1 presents the number of layer facilities and total USDA-based animal
units (USDA AUs) using the 1997 Census of Agriculture (USDA NRCS, 2002). According to
USDA NRCS (2000), the number of birds per USDA AU ranges from 250 for layers to 455 for
pullets less than three months old. To convert the total USDA AUs (in Table 4.4.5-1) to birds
count, EPA estimated a conversion factor that represented both pullets and layers. Using the
three smaller size classes in Table 4.4.5-1, EPA developed a conversion factor of 310 head per
USDA AU. The Agency developed this conversion factor so that the average head count per
operation (last column in Table 4.4.5-1) for these three size classes was near the middle of the
size class interval. Lacking specific data to directly compute the average head count for either of
the larger two size classes, EPA selected a mid-value (i.e., 350,000 head) for the 100,000-
4-49
-------
599,999 size class. With this information and the assumption that 101 of .the 671 facilities with
more than 1,000 EPA* AUs had more than 600,000 head, EPA was able to estimate the average
head count for the largest size class.
Table 4.4.5-1
Layer Facility Demographics from the 1997 Census of Agriculture Database
Size Class
Medium 1
Medium 2
MediumS
Large 1 and „
Large 2
Total
• 1 1 r
Number of
'^Facilities ,
776 '
446
238
67,1'
, 1 = 4 ' " *f'
2,131 ... .
Total
USD A AUs .
95,648
88,817
69,379
922,558
.. 1,176,402
Size Class Interval
(Number of Head)
Lower
30,000
50,000
: "'75,000
100,000
Upper
49,999
74,999
99,999
599,999
^600,000
. •- -
• -•
Average Bead
'Count per
Operation
38,210
61,734
90,368
350,000
856,368
Source: USDA NRCS, 2002.
•Section 4.3.5 documents the methodology-used to estimate that 101 of-the 671 facilities with more than 1,000 EPA AUs had
more thari'600,000 head. ". ~~"
To analyze the alternative layer thresholdsultimately'"adopted by EPA, the smallest
dry layer size class was expanded to include operations from the 25,000-49,999 size class. Also,
the division between the third and fourth dry layer size class was changed from 100,000 to
82,000. Section 4.3.5 describes the approach used to adjust the number of operations per size
class. Correspondingly, EPA recomputed the average head based on the number of operations
that were removed or added to each size class. The resulting average head count per operation
for dry layers is presented in Table 4.4.5-2. The average head count for wet layer operations with
9,000-29,999 head was estimated as the midpoint, or 19,500 head. The average head count for
wet layer operations with 30,000 or more head was estimated as 146,426 head.
4-50
-------
Table 4.4.5-2
Average Head Count for Layer Operations
Size Class
"t: Size Class Interval
(Number of Head)
Lower
Upper
Average Head Count per Operation
Dry Layer Operations
Medium 1
Medium 2
Medium 3 ,
Large 1
Large 2
25,000
50,000 -
. . 75,000
82,000
49,999 •--• •
.,.•- 74,999
81,999 .
599,999
^600,000
36,068
61,734
78,546
291,153
856,368
Wet Layer Operations
Medium 1
Large 1
9,000
29,999
;>30,000
19,500
Turkeys
Table 4.4.5-3 presents the number of turkey facilities and total USDA AUs using
the 1997 Census of Agriculture (USDA NRCS, 2002). According to USDA's NRCS (2000), the
number of head per USDA AU ranges from 50 for breeding turkeys to 67 for slaughter turkeys.
To convert the total USDA AUs (in Table 4.4.5-3) to head count, EPA estimated a conversion
factor that represented both breeding and slaughter turkeys. Using the three smaller size classes
in Table 4.4.5-3, EPA developed a conversion factor of 54 head per USDA AU. The Agency
developed this conversion factor so that the average head count per operation (last column in
Table 4.4.5-3) for these three size classes was near the middle of the size class interval. The
average head count for the largest size class was directly calculated using the conversion factor.
4-51
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Table 4.4.5-3
Turkey Facility Demographics from the 1997 Census of Agriculture Database
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Number of
Operations
875
478
262
388
2,003
Total
USDAAUs
360,475
306,632
230,628
915,367
1,813,102
Size Glass Interval
(Number of Head)
Lower
16,500
27,500
41,250
.;-:,,/;.;irpj>er--"" .'••
27,499
41,249
54,999
;>55,000 .
Average Head
Count per
Operation
22,246
34,640
47,534
127,396
Source: USDA NRCS, 2002.
Broilers
USDA NRCS (2002) provided information to EPA on the number of broiler
facilities and total USDA AUs using the 1997 Census of Agriculture based on the following
classifications:
Operation size:
Land availability:
Location:
Nutrient basis:
;>100,000 head, 50,000-99,999 head, and 30,000-
49,999 head.
No excess manure nutrients (Category 1 farms with
sufficient crop or pasture land).
Excess manure nutrients, with acres (Category 2
farms with some land, but not enough land to
assimilate all manure nutrients).
Excess manure nutrients, no acres (Category 3 farms
with none of the 24 major crop types identified by
NRCS).
Ten states or groups of states.
Applications are based on nitrogen (N) or
phosphorus (P) application rates.
4-52
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Table 4.3.5-17 in Section 4.3.5 presents the number of facilities for each
classification combination. According to USDA's NRCS (2000), the number of head per USDA
AU is 455 for broilers. EPA used this conversion factor to convert the USDA NRCS data to
number of birds:" Total munber of birds was disaggregated using a procedure that corresponds to
the procedure described in Section 4.3.5 (to disaggregate broiler facilities) for each modeled size '
class and individual state. These results were aggregated into regions, and then ultimately into
modeled regions as summarized in Tables 4*5:4 and 4.4.5-5 for nitrogen- and phosphorus-based
application rates. Approximately 87 percent of all broiler operations with more than 30,000 bird
spot capacity were located in the South a^dMid-Atlantic regions in 1997 (USDA NASS,'1999b).
111686'^°. I!giCmS W6re seiected;as ^ kgy regiohs^mce climate is not a major factor in
estimating costs at broiler operations (wMcn have total confinement buildings and generally have
covered manure storage)", total number of operations from the Midwest, Central and Pacific
regions was divided equally among the South and Mid-Atlantic regions for modeling purposes. "
Table 4.4.5-4
Final Number of Broilers per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure
South
Legion ,
lantic
=====
Land AvaUability
Category
No excess
Excess, with acres
Excess, no acres
No excess
Excess, with acres
Excess, no acres
=====
======
Medium 1
-. 39,786
39,842
39,609
39,075
39,414
39,419
=====
=====
Medium 2
55,963
58,359
56,176
54,921
57,684 •
57,557
====
=====
Medium 3
85,865
89,574
86,342
84,423
88,640
88,516
=====
Large 1
125,000
133,430
151,184
125,000
134,913
132,017
=====
=====
JLargel
273 909
329,505
381,884
251,127
314,098
325,838
=— , — i
4-53
-------
Table 4.4.5-5
Final Number of Broilers per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure
Region
Land Availability
Category
Medium 1
Medium 2
Medium 3
Large 1:
Large 2
Mid-Atlantic
No excess
39,642
55,618
85,355
125,000
Excess, with acres
39,851
58,110
89,171
132,696
Excess, no acres
39,609
56,176
86,342
149,292
219,247
326,246
385,154
South
No excess
38,845
53,886
82,820
125,000
Excess, with acres
39,427~
57,644
88,596
135,091
219,247
312,224
4.4.6
Average Head - Swine Operations
USDA NRCS (2002) provided information to EPA on the number of swine
facilities and total USDA AUs using the 1997 Census of Agriculture based on the following
classifications:
Operation, size:
Land availability:
Location:
Nutrient basis:
^2,500 head, 1,250-2,499 head, and 750-1,249
head.
No excess (Category 1 farms, with sufficient crop or
pasture land).
Excess, with acres (Category 2 farms with some
land, but not enough land to assimilate all manure
nutrients).
Excess, no acres (Category 3 farms with none of the
24 major crop types identified by NRCS).
Eleven states or groups of states.
Applications are based on nitrogen (N) or
phosphorus (P) application rates.
4-54
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Table 4.3.6-1 in Section 4.3.6 presents the number of facilities for each
classification combination. While USDA NRCS (2002) provided information by region, size
class, and land availability category, it did not provide data to.estimate average head count by
operation type (i.e., farrow-to-finish, grow-finish) or the number of operations by manure storage
(i.e., pit storage, lagoon, evaporative lagoon). Thus, it was necessary to estimate a conversion
factor that represented both breeding hogs and hogs for slaughter to convert the total USDA AUs
to head count. According to USDA NRCS (2000), the number of head-per USDA AU ranges
from 2.67 for breeding hogs to 9.09 for hogs for slaughter. Using summary :data provided by the
USDA NRCS (2002), EPA developed a conversion factor of 6 head per USDA AU, in order to
convert the USDA NRCS data to number of head. Total head were disaggregated using the same
procedure as described in Section 4.3.6 (to disaggregate .swine facilities) for each modeled size
class and individual state. These results were aggregated info regions, andlhen ultimately into
modeled regions, as summarized in Tables 4.4.6-1 and 4.4.6-2 for nitrogen-and phosphorus-based
application rates, respectively.
Table 4.4.6-1
Final Number of Swine per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Nitrogen-Based
Application of Manure
; Region
Central
NA - Not applicable. '
Land Availability
" Category
No excess
Excess, with acres .
Excess, no acres
No excess
Excess, with acres
Excess, no acres
No excess
Excess, with acres
Excess, no acres
=====
Medium 1
NA
NA
NA
889
1,031
976
871
950
976
==^==
Medium 2
NA
NA
NA
1,368
1,554
1,477
1,332
1,465
1,522
Medium 3
NA
NA
NA .
1,900
2,158
2,051
1,898
2,035
2,114
Large 1
2,500
3,696
4,999
2,664
4,581
4,424
2,505
3,457
4,561
6,553
11,065
34,944
7,838
13,713
14,929
5,927
12,132
16,982
4-55
-------
Table 4.4.6-2
Final Number of Swine per Operation Based on Modeled Region,
Land Availability Category, Operation Size for Phosphorus-Based
Application of Manure
Region
Central, .
Mid-Atlantic
Midwest
Land Availability
Category
No excess
Excess, with acres '
Excess, no acres
No excess
Excess, with acres
Excess, no -acres
No excess
Excess, with acres
Medium 1
NA
NA
NA
883
964
976
863
926
976
Medium 2
NA
NA
NA
1,346
1,496
. 1,477
1,311
1,415
1,522
Medium 3
NA
NA
NA
1,888
2,077
2,051
1,885
1,965
2,114
Large 1
2,500
3,304
4,999
2,500
4,134
.4,424
• . 2,500
2,878
4,463
Large 2
6,037
9,890
34,944
6,390
12,375
14,929
5,094
, ,?,172
16,636
NA-Not applicable.
EPA decided to develop model farms for the Mid-Atlantic and Midwest regions
because over 93 percent of the facilities with more than 750 head were located in these two
regions in 1997 (USDA NASS, 1999b). EPA added additional model farms in the Central region
based on comments received on the proposed rule that many large facilities had recently located
to states in the Central region. . .
4.5
Wastewater/Dilution Water
The amount of wastewater and dilution water generated at dairies and veal
operations is needed for the design of storage and treatment technologies. The cost model
calculates the amount of wastewater generated for each model farm. Sections 4.5.1 through 4.5.4
describe the estimates of wastewater generated at dairies and veal, poultry, and swine operations
and the assumptions and equations used in the cost model. Beef feedlots and heifer operations do
not generate any wastewater under the model farm assumptions. (For the purpose of this report,
the term "wastewater" does not include rainwater runoff.)
4-56
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4.5.1
Wastewater Generation at Dairies
The cost model calculates the total amount of wastewater generated at dairies and
uses it as input for the design of storage andlreatment technologies. Wastewater, as used in the"
cost model, includes water from flushing or hosing confinement barns and milk parlors at dairies
and veal operations. Section 4.5.1 describes the equations used to calculate the wastewater
generated, and .the.different wastewater sources present at hose and flush dairies.
... T -Hose Dairies - ~r^=r --.-
Wastewater generated at hose dairies includes wash water for equipment, milk
parlor floors, and holding area floors. The cost model assumes wastewater is generated only in
the milk parlor for hose dairies, because confinement barn waste is scraped without using flush
water. Table 4.5.1-1 lists the sources of milk parlor wastewater by size class for dairies using
hose systems.
Table 4.5.1-1
Milk Parlor Wastewater Generated at Dairies Using Hose Systems
/"- £ ".Water Source :; -••;.
Bulk Tank-Manual"
Pipeline In Parlor2
Miscellaneous
Equipment3
Cow Preparation-
Manual11
Milkhouse Floor1"
Parlor and Holding
Area Flush*
Units
gal/wash
gal/wash
gal/day
gal/wash-cow
gal/day
gal/milking
.-..;;>': •"••?.;% ,; >:
Small Operations
^200^Head)
40
75
30
0.5
20
40
••;:Y.; ;-•*.•:•'••;,. . •'• " />,;•':•
Medium Operations
t2¥^00'Head) T
35
100
30
' 0.375
15
-30
.^-V^aiege' -•.-::.;.
Operations '
<* 700 Head) ;
30
125
30
0.25
10
20
„ .*.„,».,. „„„ 4 AMii WW4 *.iu\* - / , i-rfuiy JfltcatOll XlUUSllig OllU CUUlpmeill, P/
'Information taken from Midwest Plan Service - 18, Livestock Waste Facilities Handbook, p2.5
4-57
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Based on site visits, dairies milk their cows either two or three times per day;
therefore, the cost model assumes each cow is milked an average of 2.5 times per day and the
equipment is washed after each milking. The general parlor wastewater generation equation is
thus:
Parlor Wastewater (gal/day)
+
+
No. Washes * (Bulk Tank Rinse + Pipeline Rinse)
Day Wash Wash
Miscellaneous Equipment
No. Washes x Cow Preparation x Number of Dairy Cattle
Day
...,,,-. ,j ' -. _ ;..-.. , • .•
Milkhouse Floor Wash
No. Milkings x Parlor and Holding Area Flush
Day
After plugging in the values from Table 4.5.1-1, and assuming the number of
washes and milkings equals 2.5, the total wastewater generated in the milk parlor for each size
class is computed using the following equations:
<200 Head
200-700 Head
>700 Head
Parlor Wastewater (gal/day) = [2.5 washes/day x (40 + 75 ) gal/wash] + 30 gal/day +
[0.5 gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] + 20 gal/day + [40
gal/milking x 2.5 milkings/day]
. Parlor Wastewater (gal/day) = 437.5 gal/day + (1.25 gal/cow-day x Number of Dairy
Cattle)
Parlor Wastewater (gal/day) = [2.5 washes/day x (35 + 100) gal/wash] + 30 gal/day +
[0.375 gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] +15 gal/day + [30
gal/milking x 2.5 milkings/day]
Parlor Wastewater (gal/day) = 457.5 gal/day + (0.9375 gal/cow-day x Number of Dairy
Cattle)
Parlor Wastewater (gal/day) = [2.5 washes/day x (30 + 125) gal/wash] + 30 gal/day +
[0.25 gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] + 10 gal/day + [20
gal/milking x 2.5 milkings/day]
Parlor Wastewater (gal/day) = 477.5 gal/day + (0.625 gal/cow-day x Number of Dairy
Cattle)
4-58
-------
Only the mature herd is used to calculate the wastewater use in the parlor because
the wastewater use estimates are based on the number of animals passing through the parlor.
Although the dairy model farm includes calves and heifers in'.addition to the milking herd on site,
these animals are not counted in the milking herd count because they do not produce milk. To be
conservative, all mature dairy cows, both lactating and dry, are used to calculate parlor
wastewater.
Flush Dairies
Dairies using flush systems generate larger quantities of water than dairies using
hose systems. Table 4.5.1-2 lists the sources of wastewater by size class for dairies using flush
systems.
Table 4.5.1-2
Milk Parlor Wastewater Generated at Dairies Using Flush Systems8
Water Source
Bulk Tank-Automatic
Pipeline In Parlor
Miscellaneous
Equipment
Cow Preparation-
Automatic
Milkhouse Floor
Parlor and Holding Area
Flush
•','•• -.•JUiiitS''- '"•
gal/wash
gal/wash •
gal/day
gal/wash-cow
gal/day
gal/day-cow
Small Operations
(<200Head)
60
75
30
2
20
40
Medium Operations
@00-700ftead)
55
100
30
2
15
32.5
Large Operations
• (N700 Head) i
50
125
30
2
10
25
Livestock Waste Facilities Handbook, page 2.5
As with hose dairies,'the cost model assumes each cow is milked 2.5 times per day
and the equipment is washed after each milking. The general parlor wastewater generation
equation is thus:
Parlor Wastewater (gal/day)
No. Washes x (Bulk Tank Rinse + Pipeline Rinse")
Day Wash
Wash
4-59
-------
+, Miscellaneous Equipment
+ No. Washes x Cow Preparation x Number of Dairy Cattle
Day
+ Milkhouse Floor Wash
+ No. Milkings x Parlor and Holding Area Flush
Day
Afterplugging in the values from Table 4.5.1-2, the total wastewater generated in
the milk parlor for each size class is computed using the following equations:
< 200 Head Parlor Wastewater (gal/day) = [2.5 washes/day x (60 + 75) gal/wash] + 30 gal/day + [2
gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] + 20 gal/day + [40 gal/day-
cow x Number of Dairy Cattle]
! "
Parlor Wastewater (gal/day) = 387.5 gal/day + (45 gal/cow-day x Number of Dairy
Cattle) - . •
200-700 Head Parlor Wastewater (gal/day) = [2.5 washes/day x (55 + 100) gal/wash] + 30 gal/day + [2
gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] + 15 gal/day + [32.5 gal/day-
cow x Number of Dairy Cattle]
Parlor Wastewater (gal/day) = 432.5 gal/day + (37.5 gal/cow-day x Number of Dairy
Cattle) ..,-••
> 700 Head Parlor Wastewater (gal/day) = [2.5 washes/day x (50 + 125) gal/wash] + 30 gal/day + [2
: gal/wash-cow x 2.5 washes/day x Number of Dairy Cattle] + 10 gal/day + [25 gal/day-
cow x Number of Dairy Cattle]
Parlor Wastewater (gal/day) = 477.5 gal/day + (30 gal/cow-day x Number of Dairy
Cattle)
Only the milking herd is used to calculate the wastewater use in the parlor because
the wastewater use estimates are based on the number of animals passing through the parlor.
Although the dairy model farm includes calves and heifers in addition to the milking herd on site,
these animals are not counted in the milking herd count because they do not produce milk.
In addition to the milk parlor wastewater, water is used to flush the confinement
bams. The amount of water required is estimated at 100 gal/day-cow (MWPS, 1993). The
amount of wastewater generated is calculated using the following equation:
4-60
-------
Barn Wastewater (gal/day) = 100 gal/day-cow * Number of Dairy Cattle
Because only the milking herd is housed in the confinement bam for the flush dairy model farm,
only the milking herd is.counted in the number of dairy cattle. Table 4.5.1-3 presents a summary
of the wastewater generation by dairy model farm given the average head described in Section
4.4.
Table 4.5.1-3
Wastewater Generation by Dairy Model Farm
Animal Type
Dairy-Flush
Dairy-Hose
Size Class -
Medium 1
Medium 2
Medium 3
Large 1 - *
Medium 1
Medium 2
Medium 3
Large 1
•, ** ^ ?
Average Head
250
425
600
1,430
250
425
600
1,430
Parlor v,
Wastewater" ~~
(gal/day)
-9,808
16,370
22,933
43,378
692
856
1,020
1,371
Barn
Wastewater"
(gal/day) •
25,000
42,500
60,000
143,000
0
0
0
Total
Wastewater
(gal/day)
34,808
58,870
82,933
186,378
692
856
1,020
mature dairy cows, both lactating and dry, are used to calculate parlor wastewater.
4.5.2
Wastewater Generation at Veal Operations
Veal operations do not generate as much wastewater as dairies because there is no
milk parlor wastewater. Wastewater is generated at veal operations from flushing confinement
barns only. It is estimated that the amount of water required is 100 gal/day-cow, the same value
as provided for dairy barns (MWPS, 1993); therefore, the wastewater generated from veal
operations is calculated using the following equation:
Barn Wastewater (gal/day) = 100 gal/day-calf x Number of Veal Calves
4-61
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Total Wastewater Generation
The equations listed in Section 4.4 require the average number of animals as input.
Table 4.4.4-1 lists the average number of head for each model farm. The total wastewater
generated is the sum of the wastewater generated from the confinement barn and milk parlor.
Total Wastewater (gaUday) = Parlor Wastewater (gal/day) + Bam Wastewater (gal/day)
Table 4.5.2-1 shows the wastewater generation by veal model farm.
Table 4.5.2-1
Wastewater Generation by Veal Model Farm
Animal Type
Veal
Size Class
Medium 1
Medium 2
.-.' :• •-•;'.•. !
Average Head
400
540
1,080
Wastewater
(gal/day)
, 0
0
0
Barn
Wastewater
(gal/day)
40,000
54,000
108,000
Wastewater
(gal/Say)
40,000
54,000
108,000
4.5.3
Wastewater and Dilution at Dry Poultry Operations
The dilution of as-excreted manure is calculated to provide the volume of manure
and additional liquids stored. Manure is diluted with water by a dilution value of one to three. A
dilution value of one means the stored manure has roughly the same volume as the excreted
manure (e.g., layer manure that is stored in the bottom of the layer house). Broiler and turkey
manure has a 75- to 80-percent moisture content when excreted. After the manure dries, broiler
and turkey manure is usually handled as litter. However, the loss of moisture during storage is
approximately replaced by the bedding material. Thus, a dilution value of one was used to
estimate the volume of broiler and turkey manure/litter.
4-62
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4.5.4
Wastewater and Dilution at Swine and Wet Layer Operations
• - Under baseline conditions, EPA assumed a dilution value of three when the
manure is flushed to a lagoon for storage and a dilution factor of 1.2 when manure is stored in a
pit beneath the house. EPA estimated the dilution value for lagoon storage by adding together
typical slatted floor manure flush volumes (MWPS), the annual net precipitation for the lagoon
surface, and the volume of a 25-year 24-hour rainfall event. This value is multiplied by the
manure production in an approach similar to USDA NRCS (1998). Thus, an operation that
produces 1,000 gallons of manure "as excreted" actually produces 3,000 gallons of liquid wastes
after flushing. The resulting volume is the estimated total annual pumpdown volume.
As a comparison, the University of Missouri estimates annual pumpdown volumes
based on contributions~from manure, daily fresh water inputs, net rainfall, and runoff. Though
pumpdown will vary by rainfall and climate, the Missouri model predicts the dilution value used-
by EPA may overestimate the volume of effluent associated with lagoon operations. EPA decided
to use a dilution value of three'fbr baseline conditions to ensure that the amount of waste
produced and the associated manure handlmg costs were not underestimated.
A dilution value of two reflects methods of lowering the amount of dilution that
occurs (e.g., reducing wastewater volumes due to recycling of flush water and the corresponding
reduction in fresh water use; reducing or eliminating precipitation from entering the liquid waste
impoundments). A lower dilution value will result in a large reduction in the volume of liquid
manure that must be hauled, with a corresponding reduction hi hauling costs. A dilution factor of
two was assumed when manure is flushed to a lagoon for storage and the facility constructs a
secondary lagoon and installs a pump to recycle water for flushing. These practices were used to
lower the costs of Category 2 and 3 facilities with lagoons that had to haul excess manure
nutrients away from the facility.
4-63
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4.6
Manure Generation
The amount of manure generated at animal feeding operations is also needed for
the design of storage and treatment technologies. In addition to the volume generated, the
location of manure generation and collection affects the size and type of different waste
management components. For cattle model farms, the cost model calculates the amount of
manure generated for each model farm. Section 4.6.1 describes the estimates of manure
generated at beef feedlots, dairies, and veal operations and the assumptions and equations used in
the cost model. Sections 4.6.2 and 4.6.3 describes the calculation of recoverable manure at
poultry and swine operations.
4.6.1
Manure Generation at Beef Feedlots, Heifer Operations, Dairies, and Veal
Operations
The cost model calculates the total amount of manure generated using manure
characteristics and the total number of arumals^on the beef feedlots, dairies, heifer and veal
operations. Table 4.6.1-1 lists the assumptions used tojipproximate the manure generated. The
moisture content can be used to calculate the total solids content or total water content of the
manure. In practice, manure characteristics are variable; the values shown here reflect the best
available data for national estimates.
Manure Placement
The amount of manure generated is distributed among the different areas of the
operation. For beef feedlots and heifer operations, it is assumed that all manure is generated on
the drylot. For yeal operations, it is assumed that all manure from mature cattle is generated in
the confinement barn. For dairies, it is assumed that 85 percent of the manure from mature cattle
is generated in the confinement barn and 15 percent is generated hi the milking parlor (USDA,
1996). Also, at dairies, it is assumed that calves and heifers on site deposit manure on the drylot.
These estimates are based on the amount of time dairy cattle typically spend in each facility.
4-64
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Table 4.6.1-1
Cattle Manure Production and Characteristics
£3- Animal Type
Beef Cattle
Mature dairy cows
Calves^
Heifers
Veal Calves ; "
Animal
WeigbtObs)"
877
1,350 .....
350
550
275
, Manure Production
(lb/day/l,000-Ib animal)
63b
83.5b
65.8b
66b
65.8b
Manure Density
^Ob/ft3)8
62
- 62
., 62 ,
62
62
Manure Moisture
percent)
88C
- 87C
..•• 98"
87d
98°
a technical Development Document, 2002.
b Lander, C.H., D. Moffit, andK. Alt, 1998. _ . ' '_
CNCSU,1994. '" """ "'?"*." ""
EAssumes that heifers are equal to dairy cows and calves are equal to veal calves
"ASAE,;1993.
Total Manure Generation
' The cost model calculates the amount of manure generated in each area of the farm
using the following equations. Information in Table 4.6.1-2 is used for manure generation
information, and information hi Table 4.4.1-1 is used to obtain the average number of head.
Beef cattle, calves, and heifers
Drylot Manure Generated = Average Head x Animal Weight (Ibs)
x Manure Production (lb/day/l,000-lb animal)
Mature dairy cows
Milking Parlor Manure Generated = 0.15 x Average Head x Animal Weight (Ibs) x
Manure Production (lb/day/l,000-lb animal)
• ' i . . • • , t
Barn Manure Generated = 0.85 x Average Head x Animal Weight (Ibs) x
Manure Production (lb/day/l,000-lb animal)
Veal calves
Barn Manure Generated = Average Head x Animal Weight (Ibs) x
Manure Production (lb/day/l,000-lb animal)
Table 4.6.1-2 presents manure generation by model farm. Manure generation does
not vary by region.
4-65
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Table 4.6.1-2
Cattle Manure Generation by Model Farm
Animal Type
Beef
Heifers
Dairy
Veal
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Drylot
Manure" ,
Obs/dajr) ,
20,427
30,495 '
42,330
101,590
1,430,804
17,010
26,578
37,209
63,787
4,461
7,576
10,689
25,474
NA
NA
NA
Milking Parlor
Manure
(Ibs/day)
NA
NA
NA
NA
NA '
NA
NA
NA
NA
3,345
5,682
8,017
19,106
NA
NA
NA
Barn Manure
(Ibs/day)
NA
NA
NA .
NA
NA
NA
NA
NA
NA
18,958
32,200
45,427
108,266
7,238
9,771
19,543
Total Manure
(Ibs/day)
20,427
30,495
42,330
101,590
1,430,804
17,010
26,578
37,209
63,787
26,764
45,458
64,132
152,846
7,238
9,771
19,543
•For dairy farms, drylot manure includes calf and heifer waste.
Mature Cattle Head.
NA - Not applicable.
The number of calves and heifers is estimated as 0.3 x Average
4.6.2
Recoverable Manure Generation at Poultry Operations
The poultry cost model did not use estimates of manure generation to calculate
costs. Instead, estimates of recoverable manure were made. A procedure for the calculation of
on-farm nutrient production was outlined in a report by USDA NRCS (1998) and subsequently
updated (USDA NRCS, 2000). Total nutrient availability was estimated for each livestock type
by first multiplying the average confined livestock population (in animal units) by the number of
tons of manure produced (i.e., manure as-excreted) by each type of livestock, and then
4-66
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multiplying by the recovery factor. The recovery factor reflects that portion of manure that can
be collected from the confinement areas and land applied. The recovery factor recognizes that not
all nutrients may be recovered and reflects typical nutrient losses due to volatilization, nutrients
taken up by plants in grazing area^accumulation in confinement area soils, feedlot runoff, or
leaching into ground water. This result, tons of recoverable manure, was multiplied by the
number of pounds of nitrogen or phosphorus contained in one ton of manure to compute the total
pounds of recoverable nutrients. The resulting value was further adjusted for typical nutrient
losses that occur during storage and handling to generate an estimate of total available nitrogen
and phosphorus from confined livestock manure. Table 4.6.2-1 presents details of manure and
animal characteristics for poultry. '• .-:>
- Table 4.6.2-1
Poultry Manure Characteristics Used to Calculate Nutrient Production
Animal
Chicken
Chicken
Chicken
Chicken
Turkey
Operation
Broiler
Layer
Pullet
Integrated
Layer
Animal
Turnover
#
5.5.
1.0
2.0
1.0
2.5'
Average
Animal
Weight
Ib
3
4
2
4
11
Animal Unit
Conversion
#animaIs/AU
(USDA AU)
400
270
500
270
89
Manure
Production
tons/AU/yr
(USDAAU)
15
11
8
11
9
Nutrient Content
N
P
Ib/ton of manure
16
18
14
16
7
9
9
7
Regional Recovery Factors
EPA developed regional recovery factors based on state-level recovery factors
provided by USDA (see Table 4.6.2-2). The regional factor was calculated by weighting the state
recovery factor with the number of animals of each type in a given state. Table 4.6.2-3 gives an
example of the calculation of weighting factors. In Table 4.6.2-3, the number of broilers (NB) is
multiplied by the state recovery factor (RF) to produce the weighting factor. The weighting
4-67
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factor (RF * NB) is summed and divided by the total number of broilers in a region to obtain the
regional recovery factor.
Table 4.6.2-2
Poultry Regional Recovery Factors for Manure
Region
Central
Mid-Atlantic"
Midwest
Pacific
South
Recoverable Manure Correction Factor :
/.V. NVv;Chicken ^,'.;.>;\
0.95
0.97
0.94
.. 0.90
0.96
V" XV'3torljgy''../: %..•>.
0.75
0.97
0.62
0.94
0.72
Table 4.6.2-3
Example of Weighted Averaging Method for Manure Recovery Factor
State
AL
AR
FL
GA
LA
MS
SC
Number of Broilers (NB)" ;
134,027,304
172,617,806
19,973,361
149,740,420
• 20,538,744
26,313,171
617,762,696
SumofNB
523 210 806
Recovery Factor (RF)b
0.98
0.95
0.95
0.95
1.00
0.95
1.00
Sum of (Mb x RF)/sum of NB
Weighted mean = 0.960
• ->RF x NB :;,...! .:;•,.. .
131,346,758
163,986,916
18,974,693
142,253,399
20,538,744
24,997,512
617,762,696
Sumof(NBxRF)
502,098,022
•USDANASS, 1999.
bUSDANRCS, 1998.
Nutrient Losses
The values for nitrogen and phosphorus content after losses were estimated to
provide the amount of nutrients that would be present in land-applied manure and effluent. There
is no national or even regional perspective on what these values should be. These estimates are
based on a three-part assumption:
4-68
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Nitrogen losses will greatly exceed those of phosphorus primarily due to
volatilization of nitrogen compounds.
As the quality (from an automation view) and number of manure
management systems improverthe losses of nutrients, particularly nitrogen,
may increase. In other words, as the manure management system becomes
more automated, nitrogen losses through volatilization also increase.
Phosphorus amounts are present within the bottom sludge of lagoons and
ponds, and even though the sludge is not removed on a regular basis, the
phosphorus content must be considered in an application strategy. In other
words, effluent composition may not reflect actual nitrogen and
phosphorus contents in the lagoon or holding pond.
Numerous individuals from USD A, universities, and industry groups were
consulted to arrive at the "national" values for nutrient content after losses. The discussions
focused on the types of manure systems typically used by the industry in different parts of the
country, the losses typically associated with these systems (see Chapter 11, Agricultural Waste
Management Field Handbook,USDA, 1992), and the portion of the nation's livestock raised in
different parts of the country.
4.6.3
Recoverable Manure Generation at Swine Operations
The same procedure used to compute on-farm nutrient production used for poultry
(see Section 4.6.2) is used for swine. Details of manure and animal characteristics are given in
Table 4.6.3-1 for swine. EPA developed regional recovery .factors based on state-level recovery
factors provided by USDA (see Table 4.6.3-2). The regional factor was calculated by weighting
the state recovery factor with the number of animals of each type in a given state.
4-69
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Table 4.6.3-1
Swine Manure Characteristics Used to Calculate Nutrient Production
Animal
: i
Swine
Swine
Operation
Integrated
Slaughter
• ' • .: , -.-I.
Animal
Turnover
#
2.1
2.8
, Average
Animal
Weight
Ib
110
135
Animal Unit
Conversion
#animais/AU
(U§DAAU)
9
7
Manure
Production
tons/AU/yr
.(USDAAU),
15
12
Nutrient Content
N
P
Ib/ton of manure
3
3
3
3
Source: USDA NRCS (1998).
Table 4.6.3-2
Swine Regional Recovery Factors for Manure
Region
Central
Mid Atlantic
Midwest
Pacific
South
Recoverable Manure
Correction Factor
0.75
-~ -0.87
0.76
0.76
0.54
4.7
Precipitation Data and Runoff
The cost model uses precipitation data to estimate the annual direct precipitation
and runoff, the amount of direct precipitation and runoff from a peak storm, and the amount of
direct precipitation and runoff from a chronic storm. These data .are used to properly size open
storage areas, such as runoff ponds and anaerobic lagoons.
For beef feedlots, diaries, and heifer operations, the cost model includes
calculations for runoff from drylots and direct precipitation into open liquid storage areas (e.g.,
lagoons, ponds). For swine and wet layer operations, the cost model calculates costs for
4-70
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operations that have only direct precipitation into open liquid storage areas (i.e., do not have
drylots from which runoff is collected).
The cost model'does not use precipitation data to estimate incremental regulatory
costs for dry or wet poultry operations. It is assumed that all poultry operations use total
confinement and the production area is never in" contact with precipitation. Dry poultry houses
are cleaned butperiodically and the operators may have the litter hauled off site, stacked in a
is'hed, or piled outside at the edges of fields for spreading as a fertilizer. The costs for the best
management practices (BMPs) (such as covered storage and berms) used to mitigate potential
• -\r ,'
runoff from dry poultry litter are not dependent upon the amount of precipitation. The cost model
assumes that wet layer operations '..use a lagoon to store liquid manure and that operators prevent
runoff from precipitation from entering the lagoon. It is also assumed that the lagoons are sized
properly to prevent overflow from rainfall events less than the 25-year/24-hour rainfall event.
As with poultry operations, the cost model does not use precipitation data to
estimate the regulatory costs for swine operations. It is assumed that all swine operations subject
to the rule use total confinement and the production area is never in contact with precipitation,
and that operators prevent uncontaminated runoff from entering waste storage areas. The model
also assumes that swine operations use either lagoons or deep pits to store liquid wastes and that
the lagoons are sized properly to prevent overflow from less than the 25-year/24-hour rainfall
event. The methodology for estimating the costs of constructing and operating a lagoon are
presented in Section 5.4.
Runoff from drylots at beef feedlots, heifer operations, and dairies under all
options is added to the volume required for liquid storage at the operation. Runoff from the
drylot becomes contaminated with manure solids and must be collected to prevent clean surface
water from becoming contaminated. The cost model calculates the volume of runoff that must be
accommodated in the storage facility. Runoff is the only liquid waste to be stored at beef and
heifer feedlots. Dairies are assumed to keep calves and heifers on site on dry lots and to collect
runoff from these drylots. Veal cattle, swine, and poultry model farms assume that the animals
4-71
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are kept in confinement bams rather than drylpts; therefore, it is assumed that contaminated
runoff is negligible for these animal types.
4.7.1
Precipitation Estimates
The annual precipitation for each region is calculated using monthly precipitation
values from the National Climatic Data Center (NCDC, 1999) representing the wettest six months
of the year. EPA averaged all NCDC city data for each state to approximate an average monthly
state precipitation. Next, EPA calculated average regional monthly precipitation data by
averaging the state precipitation estimates in each region. Then, EPA summed the average
regional monthly precipitation over the wettest consecutive six-month period to obtain the
"wettest six-month precipitation." The average annual regional precipitation was conservatively
estimated by multiplying the wettest six-month precipitation by two (ERG, 20QOa). ,
Annual evaporation is estimated from a map of mean annual lake evaporation
(MWPS, 1997). The net regional six-month precipitation is then calculated as the difference
between six-month precipitation and one-half of the annual evaporation, shown below.
Net Six-Month Precipitation = Six - Month Precipitation -
Annual Evaporation
Rainfall depth for the 25-year, 24-hour rainfall event, the 10-year, 1-hour rainfall
event, and the 10-year, 10-day rainfall event is estimated from map contour lines (MWPS, 1997).
Table 4.7.1-1 presents the precipitation estimates for all animal groups and each region.
4-72
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Table 4.7.1-1
Precipitation Estimates
Animal
Type
All
Region
Central
Mid-Atlantic
Midwest
Pacific
South
-Wettest 6-Month
Precipitation
(in) '
6.65
21.52
11.2
23.25
25.59
25-Year, 24-Hour
Precipitation
(to)
4
5.4
5
10
8
10-year, 1-Hour
Precipitation
(in) v
1
2.1
2
1.6
3
10-year, 10-day
Precipitation ;
(in) i
' 7
• . ,9
7
6
12
4.7.2
Drylot Area Estimates
The cost model uses the area of the drylot to determine the quantity of runoff.
Runoff from the drylot is considered to be contaminated with manure solids; therefore, it requires
collection and storage. Table 4.7.2-1 presents the range of drylot area for each animal type for
which runoff is calculated. '
; Table 4.7.2-1
Drylot Area Required by Animal Type3
Animal Tfype .••;..:
Calves
Heifers
Beef Cattle
Area Required per Animal (ft?) ' "
150-300
250-500
300-500
"Midwest Flan Service - 6 (MWPS,
unpaved lots with mounds, page 1.1
Beef Housing and Equipment Handbook,
The cost model assumes the area required for each animal type equals the average
area of each range plus an additional 15 percent for storage and handling facilities and feed silage
areas (AEA, 1999). The following equation is used to calculate total drylot area per animal:
4-73
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Drylot Area (ftVanimal) = Average Area + (0.15 x Average Area)
Table 4.7.2-2 lists the calculated drylot area per animal used in the cost model.
The total drylot area for.each model farm is calculated by multiplying the average area per animal
type by the average number of head at the operation.
Table 4.7*2-2
Drylot Area Required by Animal Type Used in the Cost Model
- -./'-.- Ajfimal,:Typev - ?ti\ :.;nJ
Calves
Heifers
Beef Cattle
i^ieajRequired per Animal (ft*)
: 259
431
460
4.7.3
Total Runoff
The cost model uses the precipitation and.area of the drylot to determine the total
amount of runoff from the drylot. The cost model assumes 40 percent of the total precipitation
over the storage period will run off a drylot that is 20 percent paved (Shuyler L., 1999):
R=0.4xp x A
where:
R
P
A
Runoff volume (ft3)
Precipitation for the wettest six months (ft)
Drylot area (ft2).
Table 4.7.3-1 shows the volumes for the six-month runoff by model farm and by
region. The cost model uses these volumes to size settling basins, ponds, and lagoons.
4-74
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Table 4.7.3-1
Six-Moath Runoff Volumes
Animal Type
Beef
Dairy .:
Heifers
<* y*-"y
I^Jze Class
Medium 1
Medium 2
Medium 3
-Large!
Large 2 —
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Central
37,728
56,286
78,106
187,517
2,640,631
11,471
19,501
27,531
65,616
38,238
59,746
83,645
143,391
Wettest Six-Month Runoff (ft3) by Region
Mid-Atlantic
122,090
- 182,145
252,760
606,821
'8,545,320
37,122
63,107 •
89,093
212,338
123,740
193,344
270,681
464,025
Midwest
63,541
94,797
131,548
315,818
4,447,378
19,320
32,844
46,368
110,510
64,400
100,625
140,875
241,500
Pacific
131,905
196,788
273,079
655,604
9,232,281
40,106
68,181
96,255
229,408
133,688
208,886
292,441
501,328
South
145,181
216,594
300,563
72r,587
10,161,465
44,143
75,043
105,943
252,497
147,143
229,910
321,874
551,784
The cost model also calculates runoff volumes from the 25-year, 24-hour rainfall
event (for Options 1 through 7) and the 10-year, 10-day rainfall event (for Option 1 A). The
volume of runoff for a single rainfall event is calculated using the equation below, which assumes
that one-half inch of rain is absorbed by the drylot (MWPS, 1993):
where:
R
P
A
R =
(P - 0.5)
(12 in/ft) x A
Runoff volume (ft3)
Precipitation (in)
Drylot area (ft2).
4-75
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Table 4.7.3-2 shows the runoff volumes for a 25-year, 24-hour rainfall event by
model farm and by region, and Table 4.7.3-3 shows the runoff volumes for the 10-year, 10-day
rainfall event by model farm. The cost model uses these volumes to size settling basins, ponds,
and lagoons. " • ,.
Table 4.7.3-2
25-Year, 24-Hour Rainfall Event Runoff Values
Animal Type
Beef
Dairy
Heifers
-•-. • --- • -
Size Class
Medium 1
Medium 2
MediumS
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
.,,._.., — --•"Runoff (ft3) by Region
Central'
49,642
74,060
102,772
246,733
3,474,514
15,094
25,659
36,225
86,336
50,313
78,613
110,059
188,672
Mid-Atlantic
69,498
103,684
143,880
345,426
. 4,864,320
21,131
35,923
50,715
120,871
70,438
110,059
154,082
264,141
"Midwest
63,825
95,220
132,135
317,228
4,467,233
19,406
32,991
46,575
111,004
64,688
101,074
141,504
242,578
" Pacific
134,742
201,020
278,952
669,703
9,430,824
40,969
69,647
98,325
234,341
136,563
213,379
298,730
•512,109
" South
106,375
158,700
220,225
528,713
7,445,388
32,344
54,984
77,625
185,006
107,813
168,457
235,840
404,297
4-76
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Table 4.7.3-3
10-Year, 10-Day Rainfall Event Runoff Values
Animal
Beef
Dairy
Heifers
— •
j
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1 ••-
Medium 1
Medium 2
MediunfS
Large 1
Runoff («P)Tby Region , -
Central
7,092
10,580
14,682
35,248
496,359
2,156
3,666
5,175
12,334
7,188
' 11230
15,723
26,953 ,
Mid-Atlantic
22,693
33,856
46,981
112,792
1,588,349
6,900
11,730
16,560
- -- 39,468-
23,000 •
~—--35,937
" 50,312
- 86,250
• Midwest
21,275
31,740
44,045
105,743
1,489,078
- 6,469
10,997
15,525
37,001
21,563 •-•;
33,691 —
- 47,168
80,859
Pacific
15,602
23,276
32,300
77,545
1,091,990
, 4,744
8,064
11,385
27,134
15,813 •
24,707
34,590
59,297
South
35,458
52,900
73,408
176,238
2,481,796
10,781
18,328
25,875
61,669
35,938
56;152 '
78,613
134,766
4.7.4
Runoff Solids
Runoff from drylots contains some portion of solids. Midwest Plan Service
suggests 1.5 percent of the runoff by mass is solids (MWPS, 1993). EPA assumes 1he runoff
solids have the same waste characteristics as excreted manure. To determine the mass of solids,
EPA'Converts the total runoff volume to mass using the density of water (62.4 Ib/cf). Then, EPA
calculates the mass of solids in the runoff by multiplying the mass of runoff by 1.5 percent.
4-77
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where:
Runoff solids (cf) = RunofiF6mo cf x 62.4 Ib/cf x 0.015
Runoff6mo
62.4
0.015
= Runoff from the wettest six months of the year (cf)
= Density of water (Ib/cf)
= Proportion of runoff that is solids.
4.8
Crops and Agronomic Application Rates
The cost model estimates the amount"of nutrients that may be applied to cropland.
To make these estimations, the cost model uses data about representative crops and crop rotation
practices typical of each fann type in eachregion. .These data are used to calculate a regional
agronomic rate for each farm type. - — •-' ~ • [r
EPA developed crop nitrogen and phosphorus requirements to depict conditions of
the model farms. Extension personnef from counties with the densest populations of animals were
consulted to determine the common cropping practices. Crop yields were determined by dividing
the harvested quantity by the acreage obtained in the 1997 Census of Agriculture (USDA NASS,
1999b). For some poultry operations, yields were far below expected and were changed to reflect
expected yields found in the Agricultural Waste Management Field Handbook (USDA NRCS,
1996). Crop nutrient removal (uptake) was based on data provided by USDA NRCS (1998) for
swine and poultry operations and USDA for cattle operations (Lander C.H., D. Moffitt, and K.
Alt, 1998). The nitrogen application rates were increased to reflect the 30-percent loss of
nitrogen after land application of manure (Sutton A.L., D.W. Nelson, and D.D. Jones, 1985) due
to volatilization of ammonia. The average annual nitrogen and phosphorus crop removal and
application rates were calculated by dividing the total crop requirements over the time to
complete a full crop rotation.
Crop Nitrogen Requirements (Ib/acre) = Crop Yield (tons/acre) x Crop Uptake (lb/ton)nitrogi:n
Crop Phosphorus Requirements (Ib/acre) = Crop Yield (tons/acre) x Crop Uptake (lb/ton)pllosphonis
4-78
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Table 4.8^1 presents the representative crops, crop rotations, crop yields, crop
uptakes, and crop nutrient (nitrogen and phosphorus) requirements for all animal types by region.
Crops are not expected to vary significantly based on the size of the animal operation.
When more than one crop, in a given rotation, is grown on the land, the total crop
nutrient requirement for that land is equal to the sum of the individual crop nutrient requirements.
The cost model estimates that 70 percent of the nitrogen and 100 percent of the phosphorus in
cattle manure that is applied to the land is available for crop uptake and utilization over time
(Lander C.H., Di Moffitt, and K. Alt, 1998); therefore, the agronomic application rate is
calculated as the total crop nutrient requirement divided by the appropriate utilization factor.
Manure Application Rate^^g^ (Ib/acre) = Total Crop Nitrogen Requirements (lb/acre)-^-70%
Manure Application Ratephospllonis (Ib/acre) = Total Crop Phosphorus Requirements (lb/acre)-f-100%
When more than one crop is present, the agronomic rate is presented as the
average of the individual agronomic rates for each crop. These agronomic application rates for
nitrogen- and phosphorus-based application scenarios are used as inputs to the cost model. Table
4.8-2 presents the total crop nutrient (nitrogen and phosphorus) requirements and manure
application rates (nitrogen and phosphorus) for all animal types by region.
4.9
Excess Manure
EPA used data developed by USDA to determine the amount of excess manure at
each model farm with insufficient land to land apply all of the manure generated on the farm
(Category 2 facilities). These USDA data were developed as part of a national analysis of the
1997 Census of Agriculture data to estimate manure production at livestock facilities (Kellogg, R.
et. al., 2000). EPA applied these data to the appropriate model farms by animal types and size
classes for beef and dairy operations. Veal operations are not included in this analysis as all veal
operations are considered to have sufficient cropland to land apply all of the manure generated at
the farm. An alternative approach described in Section 4.9.2 was used to compute excess manure
nutrients for poultry and swine operations.
4-79
-------
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4-81
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Table 4.8-2
Total Crop Nutrient Requirements and Manure Application Rates
Animal
Type
Beef
Dairy
Veal
Swine
Poultry
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
All
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
Total Crop RequirementisOto/acre)
Nitrogen :
142
247
222
287
160
142
161
161
287
160
102 ,
129
97
139
178
150
150
128
99
141
99
Phosphorus
21
28 .
'25
•, . r-32
r;v ,'49. -.
21
18
18
32
49
, 27 ,
24
14
1-9
18
15
15
20
10
14
10
Manure Application Rate (Jb/acre)
•;" ;N-Based:;;>:>;
203
353. t
, 317
410
,229
203
230
230
410
229
146
185
138
198
407
215
215
183
141
412
141
,.:•;. P-Based --;>•' •
21
28
25
32
49
21
18
18
32
49
27
24
14
19
34
15
15
20
10
34 1
10 1
4-82
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4.9.1
Beef and Dairy
The. USDA provides data on the number of farms with excess nitrogen and/or
phosphorus, broken down by animal type and size class, as well as the pounds of total excess
nitrogen or phosphorus produced by these farms. Appendix E of USDA's.report Manure
Nutrients Relative to the Capacity of Cropland and Pastureland to Assimilate Nutrients: Spatial
and Temporal Trends for the United States presents manure nutrient production according to
farm type and size for 1997. This appendix identifies the total number of operations with farm-
level excess nitrogen and the total amount of excess manure in pounds of nitrogen and
phosphorus. These farm counts correspond to the sum of EPA's Category 2 and 3 farms.
However, to determine the excess for just the Category 2 farms, EPA used USDA's Table E97,
Part III, Farms with Potential Excess Manure Nitrogen, Assuming No Export of Manure from
Farm and Part V, Farms with Potential Excess Manure Phosphorus, Assuming No Export of
Manure from. Farm. This table contains the same data presented in Appendix E with a breakout
of the amount of excess manure in pounds of nitrogen and phosphorus for farms with available
cropland (Category 2) and for farms with no acres of cropland (Category 3). Table 4.9.1-1
presents the USDA data used by EPA to develop estimates of excess manure for each animal type
and size class.
EPA calculated the excess manure on a nitrogen and phosphorus basis for
Category 2 facilities by dividing the pounds of excess nutrients by the number of farms with
excess manure and available cropland from USDA's Table E97. For example, for Fattened Cattle
> 11,000 head capacity (Beef Large 2), the amount of excess nitrogen and phosphorus per farm is
calculated using the following equations:
Excess Manure on Nitrogen Basis (Ib/farm) = 114,675,269/186 = 616,534
Excess Manure on Phosphorus Basis (Ib/farm) = 86,121,090/213 = 404,324
Table 4.9.1-2 presents the estimates of excess manure by animal type and size class.
4-83
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Table 4.9.1-1
USDA Data on Manure Production at Livestock Facilities
Animal
Type
Beef
Heifer
Dairy
Size Class
Large2
Large 1
MediumS
Medium 2
Medium 1
•All
Large 1
Medium 3
Medium 2
Medium 1
* « -r ,*.f
Enterprise Type
Fattened cattle >
1 1,000-head capacity
Fattened cattle. 1,300-
t6 ll.boO-.head '
capacity
Fattened cattle 650- to
l,300rhead capacity-
Cattle other than •
fattened cattle and •
dairy cows > 300 or
more animal units . t
Dairy farms > 700-
head capacity
Dairy farms 350- to
700-head capacity
Dairy farms 0- to 350-
head capacity
Farms -ttith.-Excess Nitrogen
Manure and Cropland or
Pastureland Available
Number of
Farms
186"""
112 •
i ! ""*
—|- •- 23-J- -
965
r~ ' i
394
358
2,266
Excess Manure
Nitrogen (Ibs)
'" 114,675,269
5,984,998
--.„„!. 220,917- ••
1,718,304
31,101,658
8,124,258
9,251,390
Farms with Excess Phosphorus
Manure and Cropland or
Pastureland Available
Number of
Farms
213
355
77
1,643
530
. 596
5,409
Excess Manure
Phosphorus (Ibs)
86,121,090
10,077,337
362,238
2,138,529
17,713,995
5,183,144
6,781,325
Source: USDA Table E97, Part III and Part V.
4-84
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Table 4.9.1-2
Excess Manure Estimates by Animal Type and Size Class
Animal
Type
Beef
Dairy
Heifer :
Size Class
Large 2
Large 1
Medium 3
Medium 2
Medium 1
Large 1
Medium 3
Medium 2
Medium 1
Large 1
Medium 3
Medium 2
Medium 1
USDA Enterprise
' ' Type "- * (
Fattened cattle >
" 1 1 ,000-head capacity
Fattened'cattle 1,300- ""
to.ll;000-head
capacity
Fattened cattle 650- to
1 ,3 00-head -capacity
Dairy farms > 700-
head capacity
Dairy farms 350- to
700-head capacity
Dairy farms 0- to 350-
head capacity
Cattle other than
fattened cattle and
dairy cows > 300 or
more animal units
? •*
Excess Manure on
Nitrogen Basis (Ib/farm)
. 616;534 ;
'" ' 53,437" ~
; .. 9,605
78,938
22,693
4,083
1,781
"Excess Manure on
Phosphorus Basis
(Ib/farm)
404,324
28,387
4,704
33,423
8,697
1,254
1,302
4.9.2
Poultry and Swine
USDA NRCS (2002) also provided information to the EPA regarding the total on-
farm acreage associated with different land availability classes. On-farm acreage when combined
with the average head count (Section 4.4), manure generation (Sections 4.6.2 and 4.6.3), and
crop requirements (Section 4.8) can be used to estimate the excess nitrogen or phosphorus
produced on an operation. Box 1 illustrates the procedure used by USDA NRCS (1998) and
adopted in the poultry and swine cost model to calculate nutrient loading and land application for
a typical 1,000-hog operation in the Midwest region. The animal unit (AU) conversion factor in
Box 1 represents the number of animals having a combined weight of 1,000 pounds For this
example, for integrated swine operations (generally meaning farrow-to-finish farms), the average
I 4-85
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weight of a hog is 110 pounds and the concomitant AU factor is 9.09 (1,000 Ib of animals/110 Ib
average hog weight). Each hog AU produces 14.69 tons of manure per year with a concentration
after losses of 2.8 Ib P/ton manure and 2.82 Ib N/ton manure. This example uses a regional
recovery factor of 0.8 and nutrient uptake of 25 Ib P/acre. The result is an acreage of 145 acres
for application of all of the manure at agronomic phosphorus rates for a 1,000-swine farrow-to-
finish operation. Operations with (some, but) less available .acreage (i.e., Category 2 operations)
would have excess phosphorus and would need to export the excess manure nutrients off-site. As
such, the remainder of this section describes the data used for acreage available to Category 2
farms. (Note, that acreage for Category 1 operations was calculated by determining the mass of
manure nutrients produced at the operation and,dividing it by the manure application rate as
determined by the crop nutrient needs.) .;, . .,,
Box 1. USDA's Method for Calculating Nutrient Production and Land Application
To calculate annual nutrient production:
Ib ... , no. head. tons manure .. ^ ^ Ib
Nutrient produced (—) = no. head / animal units conversion (———) x —— x nutrient concentation
AU
yr-AU
Substituting AWMFH values:
P produced (—) = 1,000 / 9.09 x 14.69 x 2.8=4,525—
yr yr
To calculate land required:
Land required (—) = P produced (—) x regional recovery factor (%) / nutrient uptake (—)
yr yr ac
Substituting values from average of MPS -18, USDA, and NCSU data:
Land required (acres) = 4,525 x 0.80 / 25 = 145 acres
ton
For layers and turkeys, USDA NRCS (2002) provided information to EPA
regarding the total on-farm acreage with manure applied (for Category 2 layer and turkey
operations) using the 1997 Census of Agriculture data. These data were organized into the
following groups:
Operations with no excess manure using nitrogen- or phosphorus-based
applications;
4-86
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Operations with no excess manure using nitrogen-based applications, but
which do not have enough acres to meet phosphorus-based applications;
Operations with excess manure using nitrogen-based applications and less
than 10 acres available for manure application; and
Operations with excess manure using nitrogen-based applications and 10 or
more acres available for manure application.
EPA calculated the average acreage for Category 2-operations (using nitrogen-
based applications)! as the ratio .of the total acreage to number of operations for farms with excess
- • " •• • ~ i.
manure using nitrogen-based applications and 10 or more acres available for manure application
(see Table 4.9.2-1). For example, layer operations with 500 to 750 animal units have an average
of 83.3 acres (=14,998/180). Due to Census of Agriculture disclosure restrictions, USDA NRCS
had to aggregate the first two groups described above in numerous instances. In these instances,
EPA assumed that 80 percent of the operations .from-the combined group together with the
Category 2 operations using nitrogen-based applications would be used for the Category 2
operations using phosphorus-based applications (see Table .4.9.2-1). Based on ratios of
operations, the acreage for the largest layer size class in Table 4.9.2-1 was disaggregated to 217.1
and 531.2 acres for nitrogen-based applications and 332.5 and 813.5 acres for phosphorus-based
applications.
For broilers, USDA NRCS (2002) provided information to EPA on the number of
broiler facilities and on-farm acres with manure applied using the 1997 Census of Agriculture
based on the following classifications:
Operation size:
Land availability:
> 100,000 head, 50,000-99,999 head, and 30,000-
49,999 head.
No excess (Category 1 farms with sufficient crop or
pasture land).
Excess, with acres (Category 2 farms with some
land, but not enough land to assimilate all manure
nutrients).
4-87
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Table 4.9.2-1
On-Farm Acreage for Category 2 Layer and Turkey Operations
Animal
Type
Layers
Turkeys
Size
Class
(AUs)
300-500
500-750
750-1000
>1000
300-500 "
500-750
750-1000
Farms with Excess Manure and 10 or More
Acres Available for Manure Application
Using Nitrogen-based Application
Number of '
Operations
349
J80 ...
96
278
= 464
289
139
Total
• Acreage
22,534
.14,998 , ,
11,267'
73,500
5T,32"(T~
40,584
26,516
Average
-Acreage '--•*
64.6
83.3
. 117.4
264.4
_ 1T49--
' 140.4
190.8
271.1
"Acres Ayailable^jtoir ; Manure^pliratibn
Using Phosphorus-based Application
' Numberpf;^'
Operations- ;
515
249a
124"
336a
"' ' '! 577"
317"
161'
238
Total
Acreage
67,108
43,000" :„ .
33,612a
136,208"
121,712'
67,587"
56,356"
133,275
_. - .(Average •'• ••:
...... Acreage' -•.
130.3
. _172.8
271.1
404.9
211.0
213.2
349.2
560.0
Due to Census or Agriculture disclosure resmcnons, uiw UHUUUIGU upuauuua wm» n« u/K\/»rc *»»-.—- «,...„ e,—
phosphorus-based applications and operations with no excess manure using nitrogen-based applications but nothaving enough;
acres to meet phosphorus-based applications. In 'these instances, EPA assumed that 80 percent of the operations from the
combined group together with the Category 2 operations using nitrogen-based applications would be used for the Category 2
operations using phosphorus-based applications:-— — —..-•.- .-..
Excess, no acres (Category 3 farms with none of the
24 major crop types identified by NRCS).
• Location:
• Nutrient basis:
Ten states or groups of states.
Applications are based on nitrogen (N) or
phosphorus (P) application rates.
Section 4.3.5 presents the number of facilities for each classification'combination.
Only the calculations for Category 2 acreage are presented here because Category 3 acreage is
zero and Category 1 acreage is calculated using the equation presented in Section 4.10. Total on-
farm acreage with manure applied (to Category 2 operations) was disaggregated using the same
procedure as that described in Section 4.3.5 (to disaggregate broiler facilities) for each modeled
size class and individual state. EPA disaggregated these results into regions, and then ultimately
into modeled regions, as summarized in Table 4.9.2-2.
4-88
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Table "4.9.2-2
On-Earni: Acreage with Manure Applied for Category 2 Broiler Operations
„ Region
Mid-Atlantic
South
Mid-Atlantic
South
Nutrient Basis
Nitrogen
Nitrogen :
Phosphorus
Phosphorus
Acreage in each Size Class
i8o;ooo+
226.9
214.4
356.2
230.9
125,000-
179,999
128.7
129.5
209.0
139.3
75,000-
124,999
118.8
112.5
184.0
124.6
50,000-
,74,999,
85.7
80.3
131.3
90.2
37,750-
49,999
65.6
70.3
108.7
77.5
For swine operations, USDA NRCS (2002) provided information to EPA on the
number of swine facilities and on-farm acres with manure applied using the 1997 Census of
Agriculture based on the following classifications:
Operation size:
Land availability:
Location:
Nutrient basis:
>2,500 head, 1,250-2,499 head, and 750-1,249
head.
No excess (Category 1 farms with sufficient crop or
pasture land).
Excess, with acres (Category 2 farms with some
land, but not enough land to assimilate all manure
nutrients).
Excess, no acres (Category 3 farms with none of the
24 major crop types identified by NRCS).
Eleven states or groups of states.
Applications are based on nitrogen (N) or
phosphorus (P) application rates.
Section 4.3.6 presents the number of facilities for each classification combination.
Only the calculations for Category 2 acreage are presented here because Category 3 acreage is
zero and Category 1 acreage is calculated using the equation presented in Section 4.10. Total on-
farm acreage with manure applied (to Category 2 operations) was disaggregated using the same
procedure as that described in Section 4.3.6 (to disaggregate swine facilities) for each modeled
4-89
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size class and individual state. EPA aggregated these results into regions, and then ultimately into
modeled regions, as summarized in Table 4.9.2-3. While USDA NRCS (2002) provided
information by region, size class, and land availability category, it did not provide data to estimate
acreage by operation type (i.e., farrow-to-finish, grow-finish) or the number of operations by
manure storage (i.e., pit storage, lagoon, evaporative lagoon). The acreage of category 1
operations was calculated by determining the mass of manure nutrients produced at the operation
and dividing it by the manure application rate as determined by the crop nutrient needs.
Table 4.9.2-3
On-Farm Acreage with Manure Applied for Category 2 Swime Operations
Region
Central
Mid-Atlantic
Midwest
Central
Mid-Atlantic
Midwest
Nutrient Basis
Nitrogen
Nitrogen
Nitrogen
Phosphorus
Phosphorus
Phosphorus
5,00(fr
323.0
236.4
387.7
725.2
525.2
895.8
2,500-
4,999
107.9
79.0
106.4
242.3
175.5
289.4
1,875-
2,499
n/a
70.2
103.1
n/a
181.3
285.2
1,250-
1,874
n/a
50.6
74.2
n/a
130.5
205.3
750-1,249
n/a
44.0
56.9
n/a
151.2
145.8
4.10
Data on the amount of land available to facilities for land application of manure are
limited and vary significantly by animal sector, region, and size class. This subsection presents the
methodologies used to calculate the total amount of land available for land application of manure
for the beef, and dairy sectors and the amount of land available for application of liquid wastes for
the different land-availability categories. Please refer to Section 4.9.2 for information related to
on-farm acreage available for manure application at swine and poultry facilities.
For Category 1 farms, the land requirement is calculated using the nutrients
generated and the crop uptake. The same basic approach is used for Category 2 farms, but the
4-90
-------
fraction of manure nutrients hauled off-site is subtracted from the^otal manure nutrients
generated. For both Category 1 and 2 farms, N generation and N uptake are used for N-based
nutrient management, and the corresponding P values are used for P-based nutrient management.
These calculations are essential to determining the amount of excess manure nutrients generated.
Note that a Category 1 farm using N-based application rates might be a Category 2 farm using P-
based application rates. Category 3 farms have no available land'and it is assumed that all manure
nutrients are hauled off site.
4.10.1 Total Available Cropland Acres at Beef Feedlots, Dairies, Heifer and Veal
Operations and Category 1 Swine and Poultry Acreage
The cost model performs a number of calculations to determine for each model
farm the total acreage that is available to land apply manure and the amount of manure requiring
off-site transportation. The same methodology is used for both beef and dairy animal sectors.
The acreage calculations are performed for both nitrogen-based and phosphorus-based application
scenarios. ...
Category 1 Acreage
Category 1 acreages are calculated using the agronomic application rates, number
of animals, manure generation estimates, nutrient content of the manure, and manure
recoverability factors:
Category 1 Acreage = Animal Units (AUsI x Manure Generation ftons/AUl x Nutrient Content (Ibs/ton manure) x Recoverabilitv Facto
Agronomic application rate (Ib/acre)
EPA defines recoverability factors as the percentage of manure, based on solids content, that
would be practical to recover. Recoverability factors are developed for each region using USDA
state-specific recoverability factors, and are based on the assumption that the decrease hi nutrient
values per ton of manure mirrors the reduction in solids content of the recoverable manure
(Lander C.H., D. Moffitt, and K. Alt, 1998).
4-91
-------
Category 2 Acreage
' '"Category 2 acreages are calculated using Category 1 acreages, the estimate of
excess manurefromtlSDA^iialysis described1 in Sec'tion'^and Seres required to land apply
excess manure:
~ •' :" '" ''""'" r Excess Nutrients (Ibs/yr)
Average. Excess Nutrients (Ibs / yr) = Number of Category 2 Facilities
f
Excess Acreage =
Average Excess Nutrients (Ibs/ yr)
Agronomic Application Rate (Ib / acre)
Category 2 Acreage = Category 1 Acreage Excess Acreage
: ' » ! '
Table 4.10.1-1 presents Category 1 and 2 acreages by animal type, size group, and region.
Category 3 Acreage
Category 3 acreages, by definition, are zero.
Liquid Land Application Acres
The cost model calculates the minimum amount of acreage required to land apply
all of the liquid wastewater to determine the costs of the equipment required to apply liquid waste
(see Section 5.8 for a detailed discussion of the land application costs). The number of acres
required to apply liquid waste from ponds and lagoons is based on two main variables: the
hydraulic loading capacity of the cropland and the nutrient assimilative capacity of the crops. The
cost model calculates the number of required liquid acres in four steps. The first step
4-92
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Table 4.10.1-1
Category 1 and 2 Total Acreages
for Beef Feedlots, Dairies, Heifer and Veal Operations
Option 2
1"
Animal
Beef
Dairy
Farm
Type
Beef
Flush
Size Class
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid- Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Category 1 Acreages
N-Based
307
164
182
155
252
4323
2305
2562
2189
3552
62
33
37
31
51
92
49
55
47
76
128
68
76
65
105
519
428
469
240
372
P-Based
. 1930
1327
1525
1317
776
27175
18690
21479
18544
10928
388
267
307
265
156
579
398
458
395
233
804
553
635
549
323
1991
2132
2337
1242
697
Category 2 Acreages
^ N-Based
43
12
14
25
19
1282
557
619
685
858
14
6
6
8
9
45
22
24
23
34
80
41
46
41
63
130
85
126
48
27
P-Based
. , : 579
326
374
417
190
7930
4423
5083
5721
2586
164
101
116
116
59
355
232
267
246
136
580
387
445
399
226
401
313
518
182
8
4-93
-------
Table 4.10.1-1 (Continued)
Animal
Dairy
cont.)
Farm
Type
Flush
Hose
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Region
Central
Vlid-Atlantic
viidwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Category 1 Acreages
N-Based
91
75
82
42
65
154
127
139
71
110
218
180
197
101
156
519
428
469
240
372
91
75
82
42
65
154
127
139
71
110
218
180
197
101
156
P-Based >
348
373
409
217
122
592
634
695
369
207
835
895
981
521
293
1991
2132
2337
1242
697
348
373
409
217
122
592
634
695
369
207
835
895
981
521
293 .
N-Based .
71
57
64
32 .
47
42
29
41
16
11
106
81
98
45
57
130
85
126
48
27
71
57
64
32
47
42
29
41
16
11
106
81
98
45
57
P-Based
288
305
340
177
96
179
161
222
94
28
422
421
507
245
113
401
313
518
182
8
288
305
340
177
96
179
161
222
94
28
422
421
507
245
113 1
4-94
-------
Table 4.10.1-1 (Continued)
f°5Animal
Heifers
Veal
Farm
Type"
Heifers
Flush
Size Class
Large 1
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
,
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central .
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic ,
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Category 1 Acreages
N-Based
74
61
61
38
61
20
16
16
10
16
31
25
25
16
25
43
35
35
22
36
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
P-Based
432
458
458
295
174
115
122
122
79
46
180
191
191
123
72
252
267
267
172
101
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
Category 2 Acreages
N-Based '
65
53
53
33
53
11
8
8
6
8
22
17
17
11
18
34
28
28
18
28
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o
P-Based
370
387
387
254
147
53
51
51
37
19
118
120
120
82
46
190
197
197
131
74
0
0
0
0
0
0
0
0
0
0
0
0
0
0
o
4-95
-------
calculates the hydraulic loading rate using standard engineering equations (Tchobanoglous,
George and F.L. Burton, eds., 1991). The second step calculates the minimum acreage required
to apply the liquid manure at the hydraulic loading rate. The third step calculates the minimum
acreage required to apply the liquid manure at the liquid-nutrient loading rate. The fourth and
final step compares the acreage required under the hydraulic loading and.liquid-nutrient loading
scenarios and selects the maximum number of acres as the acres required for liquid land
application. Each of these steps is described below. " "~
Step 1)
Calculate the Hydraulic Loading Rate
The cost model uses the foilowing'equation to calculate the amount of wastewater
that can be applied and used by the crops and soil per acre per,year. Using this equation in
combination with the total amount of liquid wastewater generated per year, the cost model
calculates the total number of acres ne'eded to apply all of the liquid waste.
',!.''
Hydraulic Loading Rate (ft/yr) = Evapotranspiration Rate - Precipitation Rate + Percolation Rate
Evapotranspiration Rate: EPA calculated the evapotranspiration rate using data
found in Metcalf and Eddy for select cities in the United States that correspond to
the five regions used in this analysis. Evapotranspiration rates for cities located in
the same region were averaged together. Table 4.10.1-2 presents the
evapotranspiration rate used in the cost model by region.
Precipitation Rate: To best estimate the hydraulic loading rate, Metcalf and Eddy
suggests using precipitation data from the wettest year over the past 10 years. For
this analysis, EPA used data found at the National Climatic Data Center (NCDC)
web site for 1994 through 1999. The data included weighted annual rainfall for
each state in the United States. The stations were averaged by state and by region.
By averaging the regions and comparing the average rainfall in the United States
for each year, EPA determined that 1996 was the wettest year. Table 4.10.1-3
lists the regional precipitation rates for 1996. Note, the rates used in this analysis
are not weighted; each data point contributes equally to the regional weighting.
4-96
-------
Table 4.10.1-2
Evapotranspirattion Rate
Region
Central
Mid-Atlantic
Midwest
Pacific
South
'- "•' ..-•-. •. : •".••. ••"i'~"'--'j
-; . '.City • .'...;
Paris, TX
Brevard, NC
Hanover, NH
Seabrook, NJ
Central MO
Central Valley, CA
Southern Desert, CA
JonesbotOj GA
Evapotranspiration Rate
:^,-,:- ;>:C;(ta/yrK,- -::::>.:•-
35,7
24.2
24.8
27.6
35.3
49.4
• 82.8
34.4
Regional Evapotranspiration
,':.";":-- /'^Rate^n/yr):-.^ ':-:
35.7
25.5
35.3
66.1
34.4
Source: Tchobanoglous, G. et al.1991.
Table 4.10.1-3
1996 Average Regional Precipitation
'• •"•'• "Region'^?- =,':'•
Central
Mid-Atlantic
Midwest
Pacific
South
Annual Precipitation Rate
W-,- ^i^;*^,;- ,|
17.87
57.13
33.89
39.96
53.00
Source: NCDC (http://www.ncdc.noaa.gov).
Percolation Rate: The following equation, taken from Metcalf & Eddy, is used to
calculate the rate at which liquid moves through the soil.
Percolation rate (in/yr) = Soil Permeability (in/hr) x Average Time of Irrigation (hr/day) x
Days of Irrigation (day/yr) x Percolation Reduction (%)
Soil Permeability: EPA identified the principal state soil type for each model farm.
Using USDA's soil descriptions for each of these state soils (USDA NRCS,
200Ib), EPA then identified the soil's permeability (e.g., rapid, very rapid) and
matched it to established USDA soil permeability ranges (USDA NRCS, 2001 a).
Following the procedure suggested in Metcalf and Eddy. EPA used the minimum
4-97
-------
value in the range as the soil permeability. Table 4.10.1-4 presents the values for
each region.
Table 4.10.1-4
Regional Soil Permeability
Animal
Beef
Dairy
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
Soil Type
Houston Black (XX)
Hazleton (PA) . .
Hamey(KS)
San Joaquin (CA) • •-
MyakkaOFE) :~
Houston Black (XX)
Honeoye (NY)
Antigo (WI) , , ,
San Joaquin (CA)
Myakka(FL)
; Permeability Class
Slow-
Moderately Rapid to Rapid
Moderately Slow.
Very Slow • ~ - • ~ . .
Moderately Rapid to Rapid
Slow
Moderate
Moderately Rapid
Very Slow-
Moderately Rapid to Rapid
Permeability Range
>-V ^Xta/hi-rv _
0.06
2
0.2
0.0015
2
0.06
0.6
2
0.0015
•' 2
0.2
20
0.6
0.06
20""
0.2
2
6
0.06
20
Average Time of Irrigation: EPA assumed this to be the length of one working
day (10 hr/day as per the cost model).
Davs of Irrigation: EPA assumed that farms irrigate cropland weekly and they are
not permitted to irrigate while the land is frozen. Table 4.10.1-5 shows the days of
irrigation assumed for this analysis.
Percolation Reduction: EPA assumed the percolation reduction to be 4 percent
based on the recommended value for preliminary design in Metcalf and Eddy.
Table 4.10.1-6 presents the results of the hydraulic loading rate calculations for
Option 2.
4-98
-------
Table 4.10.1-5
Days of Irrigation
Animal
Beef
Dairy
Region
Central
Mid-Atlantic
Midwest
Pacific
South '
Central
Mid-Atlantic
Midwest
Pacific
South
Freeze-Free Bays8
(days/yr)
191
161 .
•171
257
i'j ' ' ?'
320
226
153
141
256
320
Days Between
Applications
(days)
7
7
' 7
7 '
7
7
7
7
7
7
Annual Application
(applications/yr)
27
J 23
24 .
37
46
32
22
20
37
46
•From ERG, 20003
4-99
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Step 2)
Calculate the Minimum Acreage Required to Apply the Liquid
Manure at the Hydraulic Loading Rate
The following equation calculates the minimum acreage required to apply the
liquid manure at the hydraulic loading rate. The liquid manure"volume is obtained from the cost
model. Table 4.10.1-7 presents the results of the hydraulic loading rate based on the acreage
calculations. > • :
Hydraulic Acres Required..(acres) = Liquid Manure Volume (cf/yr) / Hydraulic Loading Rate.(fl/yr) x ,
"- .' „ . Conversion^!acre/43,560 sf)
Step 3)
Calculate the Minimum Acreage Required to Apply the Liquid
Manure at the Liquid-Nutrient Loading Rate
The following equation calculates the amount of liquid manure that can be applied
per acre of cropland, accounting for the amount of nitrogen or phosphorus that can be used by the
crops. '
Liquid-Nutrient Acres Required (acres) = Total Volume of Liquid (cfyr) x
Nutrient Concentration in Liquid -Agwaste (lb/cf)/ Crop Nutrient Requirements (Ib/acre)
The crop nutrient requirements are the same as the values used to calculate the
total available acreage, and vary by animal type and region. Nitrogen and phosphorus values for
lagoon/pond water are fixed at 0.01249 lb/cf and 0.00359 Ib/cf, respectively (USDA NRCS,
1996).
4-101
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4-104
-------
Table 4.10.1-8 presents the results of the liquid-nutrient loading rate based acreage
calculations for Option 2 for beef feedlots, dairies, and heifer and veal operations.
Step 4:
Compare the Acreage Required Under Hydraulic Loading and
Liquid-Nutrient Loading Scenarios
The cost model uses the maximum number of acres calculated using hydraulic
loading and liquid-nutrient loading to determine the number of acres needed to apply all liquid
manure.
4.10.2
Swine and Poultry Operations
Please refer to Section 4.9.2 for information related to on-farm acreage available
for manure application.
4.11
References
AEA, 1999. George, John. Telephone discussion regarding drylot areas and clay liners.
: September 1999.
ASAE, 1993. American Society of Agricultural Engineers (ASAE). Engineering Practices and
Data: Manure Production and Characteristics. St. Joseph, Michigan. 1999.
Bocher L.W., 1999. Custom Heifer Grower—Specialize in Providing Replacements for Dairy
Herd.. Hoards Dairyman. 1999.
Cady, R., 2000. Telephone conversation with Dr. Roger Cady, Monsanto Company and Founder
of the Professional Dairy Heifer Growers Association. February 18, 2000.
Crouch, A. 1999. Telephone conversation with Alexa Crouch., American Veal Association.
October 14, 1999. - . . .
ERG, 2000a. Annual Precipitation Estimates. Memorandum from Eastern Research Group, Inc.
to the Feedlots Rulemaking Record. December 15, 2000.
ERG, 2000b. Methodology to Calculate Storage Capacity Requirements Under Option 7.
Internal memorandum.
4-105
-------
ERG, 2002. Beef Production Cycles and Capacity. Membrandum'from D. Bartram to Feedlots
Rulemaking Record. December 9, 2002.
Kellogg, R. et.al., 2000. Manure Nutrients Relative to the, Capacity of Cropland and
Pastureland to Assimilate Nutrients: Spatial and Temporal Trends for the U.S. 2000
Lander, C.H., D. Moffitt, and K. Alt, 1998. Nutrients Available from Livestock Manure Relative
to Crop Growth Requirements, Resource Assessment and Strategic Planning Working
Paper 98-1. 1998.
MWPS, 1993. Midwest Plan Service: Livestock Waste Facilities Handbook. Second Edition.
MWPS-18. Iowa State University. Ames Iowa. April.
MWPS, 1995. Midwest Plan Service: Beef Housing and Equipment Handbook. Fourth Edition,
MWPS-6. Iowa State University. Ames, Iowa. November.
MWPS, 1997. Midwest Plan Service: Dairy Freestall Housing and Equipment. MWPS-7. 6th
.Edition.
MWPS, 1997. Midwest Plan Service: Dairy Freestall Housing and Equipment. MWPS-7. 6th
Edition.
""' -•;'•-!••••••••;
NCDC, 1999. National Climate Data Center (NCDC). Normal Monthly Precipitation, 1971-
1990. National Oceanic and Atmospheric Administration. 1999.
NCSU, 1994. North Carolina State University. Livestock Manure Production and.
Characterization in-North Carolina. North .Carolina Cooperative Extension Service.
Shuyler, L., 1999. E-mail correspondence regarding feedlot area and runoff coefficients.
September 9..
Sutton, A.L., D.W. Nelson, and D.D. Jones, 1985..,Utilization of animal manure as fertilizer.
University of Minnesota Agricultural Extension Service. AG-FO-2613.
Tchobanoglous, George and Franklin L. Burton, eds. 1991. Wastewater Engineering: Treatment,
Disposal, and Reuse. Metcalf & Eddy, Inc 3rd Edition. McGraw-Hill, Inc.
USDA, 1997.U.S. Department of Agriculture, Census of Agriculture.
USDA APHIS, 1999. Part 1: Reference of 1999 Table Egg Layer Management in the U.S.
National Animal Health Monitoring System. Fort Collins, Colorado.
USDA APHIS, 2000. Data summaries of NAHMS Layer '99, prepared at request of EPA.
National Animal Health Monitoring System. Washington, DC.
4-106
-------
USDA APHIS, 2002. Queries run by Centers for Epidemiology and Animal Health prepared by
Eric Bush. March 22,2002, 2 pages.
USDA NASS, 1999. Statistical Bulletin 952. Milking Cows and Production: Final Estimates
1993-1997. 1999.
USDA NASS, 1999c. Queries run by NASS for USEPA on the 1997 Census of Agriculture data.
Washington, DC.
USDA NRCS, 1996. Agricultural Waste Management Field Handbook, National Engineering
Handbook (NEH), Part 651.
USDA NRCS, 1998. Nutrients Available from Livestock Manure Relative to Crop Growth
Requirements. Resource Assessment and Strategic Planning Working Paper 98-1.
. Accessed October 15,1998.
USDA NRCS, 2001a NSSH - Soil Properties and Qualities (Part 618). Soil Survey Division.
http://www.statlab.iastate.edu/soils/nssh/618.htm. Accessed June 14,2001.
USDA NRCS, 200Ib. Representative and State Soils. Soil Survey Division.
http://www.statlab.iastate.edu/soils/photogal/statesoils/listl.htm/. Accessed June 14, 2001.
USDA NRCS, 2002. Profile of Farms with Livestock in the United States: A Statistical Summary;
R. Kellogg; Feb 4, 2002; 31 pages
USDA NRCS. 2000. Manure Nutrients Relative to the Capacity of Cropland and Pastureland to
Assimilate Nutrients: Spatial and Temporal Trends for the United States. Washington,
DC.
4-107
-------
-------
5.0
TECHNOLOGY COST EQUATIONS
Technology cost equations calculate the direct capital and annual costs for
installing, operating, and maintaining a particular technology or practice for an animal feeding
operation. Each cost module determines an appropriate design of the system component based on
the characteristics of the model farm and the specific regulatory option. Waste volumes generated
in the wastewater, manure, and runoff input modules described in Section 4.0 are used to size
equipment and properly estimate the direct capital costs for purchasing and installing equipment
and annual operating and maintenance costs.
Estimates of capital and annual cost components are based on information
collected from vendors, literary references, EPA site visits, and/or estimates based on engineering
judgment. The following subsections describe each technology cost equation used as a basis for
the regulatory options and specifically discuss the following:
' « Description of the technology or practice;
• Design;
• Costs; and
« Results for component costs for the technology or practice.
Section 6 discusses the prevalence of the technology or practice in use at CAFOs. Appendix A
contains output tables of capital and annual costs (in 1997 dollars) for each technology or practice
component. Section 7.0 provides examples of how these component costs are used to calculate
model farm costs.
5.1
Earthen Settling Basins
Earthen settling basins are used at animal feeding operations to remove manure
solids, soil, and other solid materials from wastewater prior to storage (e.g., a pond) or further
treatment (e.g., a lagoon). The cost model assumes that beef feedlots and heifer operations use
earthen basins to collect runoff. Because high wastewater flows from flushing operations could
cause erosion in an earthen basin, dairies and veal operations use concrete settling basins
5-1
-------
(discussed in Section 5.2) to collect bam and milking parlor wastewater. The cost model includes
costs for an earthen settling basin for beef feedlots and heifer operations for all regulatory options.
5.1.1
Technology Description
An earthen basin is a shallow basin that is designed to accumulate solids. The cost
model assumes that earthen basins receive runoff from beef feedlots and heifer operations. The
basin allows solids to settle and liquids to drain. Generally, the basin is designed to handle a
wastewater flow velocity less than 1.5 feet per second, which is slow enough to allow solids to
settle. Periodic removal of the accumulated solids is necessary; therefore, access to the earthen
basin must be provided for a front-end loader or tractor. (The costs for periodic solids removal
are included in the annual costs, which are presented as a percentage of the total capital costs.)
5.1.2
Design
Earthen basins are designed to capture runoff from the beef feedlot and are
rectangular in shape. The four sides are sloped at a 4:1 (horizontalrvertical) ratio to prevent
erosion and allow for front-end-loader access to remove solids. Earthen basins are constructed of
soils that have a significant clay content (usually at least 10 percent). Figure 5.1.2-1 presents a
cross-section of the basin.
The earthen basin is constructed by excavating part of the volume required and
building embankments to construct the remaining basin volume. The variables in Figure 5.1.2-1
are defined as follows:
he
h
wc
wb
height of embankment
height (depth) of basin
width of embankment
width at bottom of basin
width at surface of basin
length at bottom of basin
length at surface of basin.
5-2
-------
w,
Excavated
Volurte
Width View
Backfill
with excavated
soil
7
\
Ground
Level
Excavated
Volume
I 1
L
Length View
Figure 5.1.2-1. Cross-Section of an Earthen Basin
Backfill
with excavated
soil
7
Ground
Level
5-3
-------
Table 5.1.2-1 summarizes the default design criteria used in the cost model.
Table 5.1.2-1
Design Parameters for Earthen Basins
Parameter^ ^
Total height (depth) required (h)
Side slopes (horizonal: vertical) (s)
Bottom width (wb)
Width of embankment (we)
Value
4 feet
4:1
12 feet
6 feet
Source: Midwest Plan Service Structures and Environment Handbook, 1987.(MWPS, 1987)
The remainder of this subsection describes the methods used to calculate the earthen basin influent
and effluent flows, volume, other dimensions, and excavation and embankment volumes, as listed
on Figure 5.1.2-1.
Earthen Basin Influent and Effluent Flows
The design volume of the earthen basin is based on the peak runoff entering the
basin, which is set equal to the peak runoff from a 10-year, 1-hour rainfall event under all
regulatory options. Section 4.7 describes the details of the runoff calculation. In addition, it is
assumed that runoff contains 1.5 percent solids (MWPS, 1993). EPA assumes that all of the solids
from the drylot are manure solids. Using these assumptions, the total amount of water and solids
entering the earthen basin are calculated as follows:
Water Entering, cubic feet = (Peak) x ( l - 0.015)
Solids Entering, cubic feet = (Peak) x (0.015)
where:
Peak = Peak runoff during 10-year, 1-hour storm event (cubic feet).
5-4
-------
The cost model assumes that earthen basins have a settling efficiency of 50
percent, and the moisture content of the settled solids is 80 percent (Fulhage, C.D. and D.L.
Pfost, 1995). The amounts of water and solids in the settled solids and basin effluent are
calculated from the following equations:
Settled Solids, cubic feet = Solids Entering x 0.5
Water in Settled Solids, cubic feet = Settled Solids x —'-—
L(1-0.8)J
Solids Exiting, cubic feet = Solids Entering - Settled Solids
Water Exiting, cubic feet = Water Entering - Water in Settled Solids
The above equations are used to calculate the amount of solids and water that leave the earthen
basin and enter a storage pond (see Section 5.5), not the volume of the basin.
Earthen Basin Volume
The required volume of the basin is calculated from the following equation
(MWPS, 1987):
where:
Surface Area =
h
Volumebasin = Surface Area x
Peak-4
Basin depth (Table 5.1.2-1 value).
Because solids from the basin are removed frequently to prevent significant
accumulation, the cost model does not include accumulated solids in the volume calculations.
Table 5.1.2-2 summarizes the earthen basin design volumes calculated for all regulatory options
by model farm.
5-5
-------
Table 5.1.2-2
Earthen Basin Volume by Model Farm for All Regulatory Options
Animal
Type
Beef
Heifer
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Earthen Basin Volume (ft3) by Region
Central
777
1,367
2,036
5,511
83,534
777
1,474
2,223
4,121
Mid-Atlantic
3,399
5,297
7,516
18,635
268,341
3,453
5,645
8,077 _..
14,145
Midwest
3,159
4,923
.7,008
17,459
251,528
3,212
5,244
7,543
13,236
Pacific
2,196
3,506
5,029
12,675
184,330
2,250
3,747
5,404
9,600
South
5,565
8,505
11,979
29,381
419,522
5,645
9,066
12,862
22,351
NA - Not applicable. No regulatory options include this component for this model farm.
Earthen Basin Dimensions
The cost model assumes that the earthen basin has four sloped sides with a
rectangular base. To determine the dimensions of the basin, the design volume of the basin from
Table 5.1.2-2 is used with the design parameters shown in Table 5.1.2-1. The following equation
is used to determine the length of the basin:
Volumebasin = J4 h [A, + A2 + (A, A2 f5]
Volumebasin = V4 h [lbwb + lsws + (l^w,,)0-5]
where:
A,
A2
Area of the bottom base =lbwb
Area of the top (surface area) = ls ws.
5-6
-------
Earthen Basin Floor Surface Area
The surface area of the floor of the basin is calculated to determine the area for
compaction. The surface area includes the bottom area plus the area of the four trapezoids that
make up the sides of the basin. Figure 5.1.2-2 depicts the surfaces of the sloped sides.
a trapezoid.
where:
The surface area of the sloped sides is calculated using the formula for the area of
Area of Side = >/4 HS (a + b)
HS = Height of the side (see equation below)
a = Bottom width (lb or wb)
b = Top width (ls or wj.
The height of the side is calculated using the Pythagorean Theorem:
HS = (h2 + (4h)2)°
The total surface area of the basin is:
Surface Areabasin = lbwb + 2 [0.5 x HS Ob + ls) ] + 2 [0.5 x HS (wb + ws)]
Earthen Basin Excavation and Embankment Volumes
Earthen basins are constructed by excavating a portion of the necessary volume
and building embankments around the perimeter of the basin to make up the total design volume.
The cost model performs an iteration to maximize the use of excavated material used in
constructing the embankments that minimizes the costs for construction. The excavation volume
is represented by the following equation:
Vol^^ = 0.5 (h-h.) [lbwb + lsws + (lbwblsws)0-5]
5-7
-------
4h.
Basin
Volume
;ide View
HS
wb
HS
Surface of Sloped Side
Surface of Sloped Side
Figure 5.1.2-2. Sloped Sides of Earthen Basin
5-8
-------
The excavated soil is used to build the embankments. Because the soil will settle somewhat, the
cost model assumes that an extra 5 percent of volume is required. The embankment volume is
represented by the following equation:
; Volembankll,ent = 2 [(1.05 h.We + s (1.05 he)2) (lb +2 sh)] + 2 [(1.05 hewe + (1.05 s)2 he2) (w + 2sh)]
The cost model calculates the dimensions of the basin that yields the desired volume.
5.1.3
Costs
Capital costs to construct and install the earthen basin consist of mobilization,
excavation, and compaction. Table 5.1.3-1 lists the unit costs for each of these elements.
Table 5.1.3-1
Unit Costs for Earthen Basins
'':",•' " , Untt/.-'':':": - -
Backhoe mobilization
Excavation
Compaction
-.. • ->.•': -'Cost
(1997 dollars)
$204.82/event
$2.02/yd3
$0.41/yd3
Source*
Means, 1999 (022 274 0020)
Means, 1999 (022 238 0200)
Means, 1996 (022 226 5720)
alnfbrmation taken from Means Construction Data. The numbers in parentheses refer to the division number and line number.
The excavation cost is calculated using the following equation:
Excavation Cost ($) = Excavation Unit Costs ($/yd3) x
Volume
excavated
(ft3)
27 (ft3/yd3)
The total volume of soil that is compacted includes the surface area times a 1-foot
compaction depth plus the entire volume of the embankment because it is compacted as placed.
Volumecompacted (ft3) = [Surface AreabKin (ft2) x l ft] + Volumeembankment (ft3)
5-9
-------
Compaction Cost ($) = Compaction Unit Costs ($/yd3) x
Volumecompacted (ft3)
27(ft3/yd3)
Total Capital Costs
The total capital cost for the earthen basin is calculated using the following
equation:
Capital Cost = Mobilization Cost + Excavation Cost + Compaction Cost
Total Annual Costs
Based on best professional judgement, it is estimated that annual operating and
maintenance costs are 5 percent of the total capital costs.
Annual Cost = 0.05 * (Capital Cost)
5.1.4
basin.
Results
Appendix A, Table A-l presents the cost model results for constructing an earthen
5.2
Concrete Settling Basins
Concrete settling basins, also called concrete sedimentation basins, are used at
animal feeding operations to remove manure solids, soil, and other solid materials from
wastewater prior to storage (e.g., a pond) or further treatment (e.g., a lagoon). Dairies use solids
separation to increase the storage volume available for wastewater in lagoons or to reduce the
moisture content of the waste to make it more suitable for transport, disposal, composting, and
other uses, such as bedding materials. The cost model includes concrete settling basins in all
options for dairies to collect barn and milking parlor wastewater because the higher wastewater
5-10
-------
flows characteristic of dairies could cause significant erosion in an earthen basin. Concrete
settling basins were not included in the cost analysis for beef feedlots, heifer operations, swine
operations, or poultry operations.
5.2.1
Technology Description
The settling basin is a shallow basin or pond that is designed to accumulate solids.
The purpose of a settling basin is to slow wastewater flow sufficiently to allow solids to settle and
liquids to drain. In general, reducing the flow velocity to less than 1.5 feet per second is enough
to allow solids to settle. Access to the settling basin must be provided for periodic removal of
solids. Solids separators can have a solids separation efficiency of between 30 percent (for
mechanical separators) and 60 percent (gravity settling basins) (Fulhage, C. D. and D.L. Pfost,
1995). EPA estimated that most solids separators used in this industry are gravity settling basins,
and used a settling efficiency of 50 percent.
Settling basins may be constructed from a variety of materials, including concrete.
Concrete construction offers the advantage of added durability and stability of side slopes. Also,
concrete construction facilitates the removal of solids with heavy equipment such as a front-end
loader, which may drive onto a concrete settling basin floor. A concrete basin design is also
advantageous in areas where soils are not suitable for earthen construction (e.g., areas where soils
have a high sand content). Concrete basins are preferable to earthen basins to prevent erosion
when high-velocity wastewater flows are anticipated, such as at flush dairies.
5.2.2
Design
Wastes entering the concrete settling basin include manure from the mature dairy
cows, wastewater from the milk parlor, and flush or hose water from the freestall barns. A
settling basin is designed to handle peak wastewater flows (NRAES, 1989); for a dairy operation,
the peak flows are assumed to occur during the flushing of one freestall barn. Settling basin size
depends upon the surface loading rate (i.e., the hydraulic load per unit of basin surface area) for
5-11
-------
agricultural wastewater; basin depth may be adjusted to allow for solids accumulation. It is
assumed that wastewater flows to the settling basin via gravity.
The concrete settling basin design consists of a rectangular basin with a sloped
ramp for front-end loader access (see Figure 5.2.2-1). The basin is 3 feet deep, allowing for 1
foot of solids accumulation. Rectangular concrete basins are typically designed with a 3:1* length-
to-width ratio (NRAES, 1989). The sloped access ramp forms one side of the basin; however, it
is longer than the other sides to allow the basin to have sufficient volume. The access ramp is
sloped 1 inch fail per 1 foot run (MWPS, 1987). The concrete thickness is 6 inches (USDA
NRCS, 1995). The sub-base for the concrete floor and access ramp consists of 6 inches of
compacted gravel fill and 4 inches of graded sand fill.; The concrete is shaped with wooden forms
and reinforced'with steel (#4 bars).
Concrete Basin Volume and Surface Area
- - , •r.f-i-r .-.• . ---'•- -••;..,
.
The required area and volume of the basin are calculated from the Midwest Plan
Service (MWPS, 1987) formulas below:
where:
Peak =
Surface Areabasin = Peak * 4
....-•i...yolurae£!jii= Surface Area x h
. v ; •
Basin depth = 3 ft (Recommended depth is 2 feet plus depth
required for solids storage. Depth of solids should not exceed 1.5
feet; therefore, EPA assumes 1 foot.) (Fulhage, C. D. and D.L.
Pfost, 1995).
Flow from flushing of confinement barn.
Using the Pythagorean Theorem,
Ramp Length = (h2 + Run2)1
,2\Si
5-12
-------
Concrete Settling Basin
(Base Cross-Section)
Figure 5.2.2-1. Concrete Settling Design
5-13
-------
where:
Run
Surface Area of Ramp
Volume Along Access Ramp
h x 12 in/ft x (1 ft run - 1 in fall)
Ramp Length x Basin Width
0.5 Fall x Run x Basin Width.
Additional basin length is needed to account for the slope of ramp.
Length = 0.5 x Run
Length^iagbium (including access ramp) = Theoretical Length + Additional Length
Lengthjetafag basin (excluding access ramp) = Length of Basin - Run
Table 5.2.2-1 summarizes of the concrete basin volumes calculated for flush and
hose dairies by size group. Note that the basin design does not vary by region or regulatory
option.
Table 5.2.2-1
Concrete Basin Volume by Model Farm for All Regulatory Options
Animal Type
Dairy - Flush
Dairy - Hose
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Concrete Basin
Volume (ft3)
7,520
12,784
18,048
43,014
416
515
614
825
5-14
-------
5.2.3.
Costs
The capital costs to construct and install the concrete settling basin include
mobilizing the backhoe used for excavation, .excavating soil, compacting the ground surface,
hauling gravel and sand to the lot, purchasing the gravel and sand, grading the sand, the form
work, reinforcement, and concrete for the walls, slab (including reinforcement), and finishing the
slab. Table 5.2.3-1 presents the unit costs for each of these components.
Table 5.2.3-1
Unit Costs for Concrete Settling Basin
Unit
Backhoe mobilization
Excavating
Hauling of material
Compaction
Gravel fill (6")
Sand fill
Grading sand
Wall form work
Wall reinforcement bars
Ready mix concrete
Slab on grade
Finishing slab (concrete)
Cost
(1997 dollars)
$204.82/event
, $2.02/yd3
$4.95/yd3
$0.41/yd3
$9.56/yd3
$48.55/yd3
$1.73/ft3
$4.90/ft2
$0.45/ft
$63.70/yd3
$116.29/yd3
SO.SS/ft2
Source8
Means 1999 (022 274 0020)
Means 1999 (022 238 0200)
Means 1996 (022 266 0040)
Means 1996 (022 226 5720)
Means 1 998 (022 308 0 1 00)
Richardson 1996 (3-5 pi)
Means 1999 (025 122 1100)
Building news 1998 (03110.65)
Richardson 1996 (3-5 p9)
Means 1998 (033 126 0200)
Means 1999 (033 130 4700)
Means 1999 (033 454 0010)
•For Means Construction Data, the numbers in parentheses refer to the division number and line number.
Mobilization
The mobilization costs are a fee per event (i.e., fee to mobilize all equipment on
site). These costs are for moving the appropriate heavy machinery and equipment.
5-15
-------
Excavation
The excavation cost is calculated from the following equations:
= Volumebasin + Volumeramp + Volumesilbsurface
Volumeexcavated (ft3)
Excavation Cost = Excavation Unit Costs ($/yd3) x 27ft3 /v d3
Compaction
The total volume to be compacted includes the surface area of the basin and the
ramp times a 1-foot compaction depth.
, = [Surface Areabasin (ft2) + Surface Area^p (ft2)] * 1 ft
Hauling
The total volume of gravel and sand needed is equal to the volume underneath the
settling basin and the ramp.
Volumegravel(yd3) = [Surface Areabasin (ft2) + Surface Area Ramp (ft2 )] x 0.5 ft x
Volumesand(yd3) = [Surface Areabasin (ft2) + Surface Area Ramp (ft2)] x 0.33 ft x
The volume of the material to be hauled includes the sand plus the gravel.
5-16
-------
Reinforcement
The concrete wall form work is calculated as follows:
g basin + Areabasin cnd 4- Area^mp sidcs
Assuming that reinforcements are spaced every 12 inches along the length and
width of the basin, the total length of reinforcement is calculated as follows:
= 2 bars/ft x [Surface Area^ + Surface Area^p
The concrete volume for the walls and slab are calculated as follows:
Volumec
-------
Total Annual Costs
Based on best professional judgement, it is assumed that annual operating and
maintenance costs are 5 percent of the total capital costs.
Annual Cost = 0.05 * (Capital Cost)
5.2.4
Results
Appendix A, Table A-2 presents the cost model results for constructing a concrete
gravity settling basin.
5.3
Berr
Beef feedlots, daMesIheifer, and'swine and dry poultry operations use berms to
contain stormwater runoff and process water that fall within the animal handling and feeding areas
and to divert clean stormwater that falls outside these areas. Because the handling and feeding
areas contain manure, runoff from these areas needs to be contained and diverted to a waste
management storage facility (e.g., a lagoon or a pond); Berms-surrounding the handling and
feeding area act as a physical barrier between the containment area and adjacent "clean" land.
Berms are costed for all beef feedlots, heifer operations, and dairies for all regulatory options, but
not costed for veal operations because they are assumed to be indoor operations.
Stormwater is diverted around poultry and swine storage structures by
constructing berms on two adjacent sides up-gradient from the storage facility or lagoon. Berms
are not included in the cost analysis for swine operations with pit systems.
5.3.1
Technology Description
Berms are earthen structures that divert clean runoff away from pollutant sources
and channel runoff that falls within the area containing pollutant sources. Runoff that falls within
5-18
-------
the containment area at beef and dairy operations may become contaminated from contact with
animal feed and fecal matter deposited in the feedlot or handling area. This runoff is channeled by
the berms to a waste management storage facility (e.g., a pond or lagoon).
5.3.2
Design
The design of a berm system for a specific operation depends on the size of the
outdoor feedlot area, lagoon, or dry waste storage area. The feedlot area is dependent upon the
number of animals contained on drylots at the facility.
Beef Feedlots and Dairies
The cost model assumes for beef feedlots and dairies that berms are constructed as
a 3-foot-high, 6-foot-wide compacted soil mound that surrounds the feedlot and animal handling
areas. EPA assumes the feed storage area is part of the animal handling areas. Figure 5.3.2-1
depicts the cross-section of the berm assumed for this cost model.
Figure 5.3.2-1. Cross-Section of Berm
The area of the cross-section of the berm is calculated using the following
equation:
5-19
-------
Area. =%xbxh
where:
b
h
Base width (6 feet)
Total height (3 feet).
The total length of the berm system for beef feedlots and dairies varies according
to the size of the feedlot area. The area required for each animal varies by animal type, because
different sized animals require a different amount of space. Table 5.3.2-1 provides the
recommended area per animal for a drylot, not including handling and storage areas. The beef
and dairy costmodel calculated the average area per animal on a drylot using the ranges presented
in Table 5.3.2-1, and added 15 percent for handling areas (AEA, 1999).
Table 5.3.2-1
Space Requirements Assumed for Animals Housed on Drylots3
Animal Type
Beef cattle
Mature dairy cows
Heifers
Drylot Area
(ft2 /animal)
400
400
375
225
Handling Area
(ftVanimal)
60
60
56
34
Total Area
(fi?/animai)
460
460
431
259
•Source: MWPS, 1993; AEA, 1999
The total perimeter of the berm is calculated as follows:
where:
Head
L = 4 x
x Head)1
,0,5
Total perimeter (length of four sides of a square area) (feet)
Total area of drylot and handling areas per animal (ft2)
(Table 5.3.2-1 value)
Average Head (Table 4.3.1-1 value).
5-20
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Table 5.3.2-2 summarizes the perimeters of the berm calculated for all model
farms. Note that the berm design does not vary by region or regulatory option.
Swine and Poultry Operations
For swine and poultry operations, berms were constructed in accordance with the
standards of the American Society of Agricultural Engineers (ASAE, 1998). ASAE specifies a
berm with a 1-foot top width, a height of 3 feet, and a 2:1 side slope. Assuming a trapezoidal
shape, the berm cross-sectional area is determined by:
bermtop
)
where:
w,
w,
bermbot"
bermtop"
height of berm
width of berm bottom
width of berm top.
Table 5.3.2-2
Berm Perimeter by Beef and Dairy Model Farm for All Regulatory Options
Animal Type
Beef
Heifers
Dairy (Heifers and Calves)
.-.••/>. . Size Class •'''-•• •-, • -
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Benfl Perimeter (ft) =
1,650
2,016
2,374
3,679
13,806
1,661
2,077
2,457
3,217
910
1,186
1,410
2,176
5-21
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With a side slope of 2:1 (H:V), a height of 3 feet (HberJ, and a top width of 1 foot
), the bottom width (Wbermb-ot) is 13 feet, and the cross-sectional area (AreabeiJ is 21
square feet. The cross-sectional area is then multiplied by berm length (L^™) to obtain cubic
yardage for construction. Berm length is determined by the dimensions of the solid or liquid
storage structure.
For solid poultry waste, the berm length is calculated from .the dimensions of ithe
litter storage shed (see 5.14). Shed width is assumed to be 68 feet and shed length is the same as
the length of the litter stack. For liquid storage systems, lagoons or evaporative ponds, berm
length is determined after a subroutine is executed to determine the lagoon or evaporative pond
dimensions (see 5.4.5). Lagoons and evaporative ponds are assumed to be square, and berm
length is calculated from the top width of these structures.
The two.adjoining berms for swine and poultry operations are designed to extend
10 feet beyond each of two adjacent sides of the storage structure.. The berms meet to form a
corner, but since the berms are 13 feet wide at the base, there is substantial overlap at the corner.
Based on a mathematical analysis of the extent of this overlap, it was determined that berm length
should be calculated in the following manner to adjust for the overlap:
For lagoons and evaporative ponds:
For solid storage structures:
where:
W =
"lagoontop
ok
320
(2 * W,agoontop + 30)
= (Volumeslack/320 + 98)
Width of top of lagoon or evaporative pond
Volume of litter stack
The cross-sectional area of the litter stack.
A more detailed discussion of berm and other calculations used for swine and
poultry operations can be found in Swine and Poultry Cost Model QA/QC Report (Terra Tech,
2002).
5-22
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5.3.3
Costs
To construct the berm, the volume of material to construct the berm is excavated
along the perimeter of the containment area. The excavated soil is mounded to form the berm and
the soil is compacted. Table 5.3.3-1 presents unit costs for constructing the berm. A fixed earth
moving cost of $2.60 per cubic yard was used in the calculation of similar expenses for berms at
swine and poultry operations.
Table 5.3.3-1
Unit Costs for Constructing Berms
Unit ''-•'-:''•'[
Compaction
Excavation
Cost
(1997 Dollars)
$0.41/yd3
$2.02/yd3
v f *° ^ *
Source"
Means, 1996 (022 226 5720)
Means, 1999 (022 238 0200)
inlormation taken from Means Construction Data. The numbers in parentheses refer to the division number and line number.
Different years were selected for the different components based on consultation with industry experts and best professional
judgement.
The total volume of the berm for beef feedlots and dairies is calculated using the
following equation:
where:
Volume ben^ysten, = Area ^ x L x 1.25 x 1.05
Area berm = Cross-sectional area of berm (square feet)
L = Total length of berm around containment area (feet)
1 -25 = Factor accounting for volumetric expansion on soil for
cut/fill (AEA, 1999)
1-05 = Factor accounting for 5% settling after compaction.
Compact Cost =
$0.41 / yd3 x Volume
27 ft3./yd3
_ . _,. $2.02 / yd3 x Volume
Excavation Cost = —
27 ft/yd3
5-23
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The volume of berms for swine and poultry operations is calculated using the following equation:
Volume^™ = Areaberm
With a cross-sectional area of 21 square feet, berm volume is:
Volumebemi = 21 *
Total Capital Cost
The total capital cost for beef feedlots and dairies, therefore, is $2.43 per cubic
yard of berm. To convert this cost to a cost per foot, the volume is divided by the berm area,
taking into account the factors for expansion and settling as follows:
$2.43/yd3 x % x 6 x 3 x 1.25 x 1.05_
Capital Cost = Cost / Linear Foot = 27ft3/ d3 ~
The cost of $1.41 per linear foot of berm is the cost included in the cost model.
A fixed earth moving cost of $2.60 per cubic yard was used to calculate the cost of
berms for swine and poultry operations. This fixed cost was multiplied by the berm volume to
determine total capital cost using the following equation:
Capital Cost = Volume^ 727 x 2.60
where the 27 converts volume from cubic feet to cubic yards.
5-24
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Total Annual Costs -
Based on best professional judgement, the total annual cost for berm maintenance
is estimated at 2 percent of the total capital costs for all animal types.
. . Annual Cost = 0.02 x (Capital Cost)
5.3.4
Results
Appendix A, Table A-3 presents the cost model results for constructing and
maintaining berais.
5.4
Lagoons
Anaerobic lagoons are used at dairies and veal, wet layer, and swine operations to
collect process water and flush water, which contain manure waste. Anaerobic microbiological
processes promote decomposition, thus providing treatment for wastes with high biochemical
oxygen demand (BOD), such as animal waste. Manure, process water, and runoff are routed to
the lagoon where the mixture undergoes treatment. New lagoons also provide storage capacity
until the waste can be applied to cropland as fertilizer or irrigation water, or be transported off
site. Section 5.9 discusses the costs associated with transporting waste off site, including solids
and liquids.
Lagoons are included in all options for dairies and veal operations, except Option 6
which replaces the lagoon with an anaerobic digester and a pond for large dairies. Options 1, 2,
4, 5 A, and 6 require zero discharge of manure, litter, or process wastewater pollutants from the
production area with the exception of overflows from a facility designed to hold all process
wastewater, including the direct precipitation and runoff from a 25-year, 24-hour rainfall event.
CAFOs that already have storage in place are assumed to have sufficient capacity. Under Options
1, 2, and 4, CAFOs that have no storage on site are costed for the installation of naturally lined
lagoons with 180 days of storage. Under Option 7, CAFOs are costed for the installation of
5-25
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naturally lined lagoons with a storage capacity that varies based on land application timing
restrictions. For Options 3A/3B and 3C/3D, CAFOs expected to have a direct hydrologic
connection from ground water to surface water are costed for the installation of anaerobic
lagoons with an artificial liner to prevent seepage of wastewater into ground water.
Lagoons are assumed as part of the baseline scenario for wet layer operations and
some swine operations with liquid-based systems. Other swine operations have pit storage or
evaporative pond systems under baseline conditions, and all other poultry operations have solid-
based manure management systems. Thus, lagoon construction is generally not included as a cost
for swine and poultry operations, with five exceptions. Under Option 1 A, increased storage is
provided to handle chronic rainfall at wet layer operations and at swine operations with liquid or
evaporative pond systems. Increased storage is provided for all swine facilities under Option 7,
and secondary lagoons are included as part of the cost to recycle flush water at Category 2 liquid
swine operations for all but Option 5. The cost model also includes construction of new, lined
and covered anaerobic lagoons under Option 5 for swine operations currently using evaporative
ponds. This alternative is less expensive than covering the evaporative ponds. In addition,
secondary lagoons with storage for 20 days are constructed hi conjunction with liner installation
for liquid and evaporative pond systems.
5.4.1
Technology Description
Anaerobic lagoons provide storage for animal wastes while decomposing and
liquefying manure solids. Anaerobic processes degrade high biochemical oxygen demand (BOD)
wastes into stable end products without the use of free oxygen. Nondegradable solids settle to
the bottom as sludge, which is periodically removed. The liquid is applied to on-site cropland as
fertilizer or irrigation water, or it is transported off site. The sludge can also be land applied as a
fertilizer and soil amendment. Anaerobic lagoons can handle high pollutant loading rates while
minimizing manure odors. Properly managed lagoons have a musty odor.
5-26
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Lagoons reduce the concentrations of both nitrogen and phosphorus in the liquid
effluent. Phosphorus settles to the bottom of the lagoon and is removed with the lagoon sludge.
Influent nitrogen is reduced through volatilization to ammonia.
; Anaerobic lagoons are typically at least 6 to 10 feet in depth, although 8 to 20 foot
depths are not unusual. Deeper lagoons typically have a smaller surface area to depth ratio, allow
less area for volatilization, provide a more thorough mixing of lagoon contents by rising gas
bubbles, and minimize odors.
Anaerobic lagoons offer several advantages over other methods of storage and
treatment. Anaerobic lagoons can handle high loading rates and provide a large volume for long-
term storage of liquid wastes. Lagoons treat the manure by reducing nitrogen and phosphorus in
the effluent and allow manure to be handled as a liquid. Lagoons are typically located at a lower
elevation than the animal barns; gravity is used to transport the waste to the lagoon, which
minimizes labor. -
Anaerobic lagoons are appropriate for use at operations that collect high BOD
waste, such as milking parlor flush or hose water and flush bam water. Typically, dairies and veal
operations operate in this manner and have lagoons for wastewater storage. The cost model
assumes all dairies and veal operations use anaerobic lagoons, some swine and poultry operations
require a lagoon, and beef feedlot and heifer operations use a storage pond (discussed in Section
5.5). The cost model also assumes that swine operations use either pit (Mid-Atlantic and
Midwest regions), anaerobic lagoon (Mid-Atlantic and Midwest regions), or evaporative pond
systems (Central region), while all wet layer operations use anaerobic lagoons. Broiler, turkey,
and dry layer operations are assumed to not use anaerobic lagoons.
Based on site visits, EPA assumes all veal operations have sufficient storage, such
as lagoons, currently in place. However, not all dairies are expected to have liquid storage
currently in place. In addition, naturally lined lagoons are more prevalent at dairies and veal
operations than synthetically lined lagoons. Section 6 provides EPA's estimates of the percentage
of dairies and veal operations that would require the installation of a lagoon, a lagoon with a liner
5-27
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(for Options 3A/3B and 3C/3D), or a lagoon with additional capacity under Option 7. Also
contained in Section 6.0 are EPA's estimates of the percentage of swine and wet layer operations
that would require increased storage under Option 1A, liners under Options 3B and 3C, and
increased storage for swine facilities under Option 7.
5.4.2
Design of Anaerobic Lagoons at Dairies and Veal Operations
The design of anaerobic lagoons for dairies and veal operations is described below.
Considerations specific to the design of anaerobic lagoons and evaporative ponds for swine and
poultry operations are discussed in Section 5.4.5.
Anaerobic lagoons are designed based on volatile solids loading rates (VSLR).
Volatile solids represent the amount of wastes that will decompose. The cost model assumes the
lagoon receives runoff directly from the calf and heifer drylots, wastewater from the barns,
wastewater from the parlor, and manure from the parlor and flush barns. The manure supplies the
volatile solids into the lagoon. Lagoons are typically constructed by excavating a pit and building
berms around the perimeter. The berms are constructed with an extra 5 percent in height to allow
for settling. The sides of the lagoon are typically sloped with a 2:1 or 3:1 (horizontahvertical)
ratio.
Considerations are also made to avoid ground water and soil contamination.
Options 1, 2,4, 5, 5 A, and 7 assume the bottom and sides of the lagoon are constructed of soil
that is at least 10 percent clay compacted with a sheepsfoot roller. Options 3A/3B and 3C/3D
require additional ground water protection; therefore, CAFOs that are located in areas of high risk
for ground-water contamination have costs for installation of an synthetic liner over a compacted
clay liner.
Lagoons are designed using the following steps:
5-28
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1) Determine the necessary storage volume of the lagoon. Lagoons are
designed to contain the following volumes (see Figure 5.4.2-1):
— Sludge Volume: Volume of accumulated sludge between cleanouts
(depends on the type and amount of animal waste),
— Minimum Treatment Volume: Volume necessary to allow anaerobic
decomposition to occur,
• • • " — Manure and Wastewater: Milk parlor and flush barn waste water
and manure and runoff from drylots,
— Net Precipitation: Annual precipitation minus the annual'
evaporation,
— Design Storm: The depth of the peak (e.g., 25-year, 24-hour)
.rainfall event,
— Freeboard: A minimum of one foot of freeboard, and
— Dilution volume (for swine and poultry operations).
2) Determine the dimensions of the lagoon, given the required storage volume
depending on the regulatory option.
3) Determine the costs for constructing the lagoon, using the dimensions
calculated in Step 2.
Freeboard
Depth of runoff from a 25-year, 24-hour storm event
Depth of normal precipitation less evaporation
Manure and wastewater volume (including runoff)
Minimum treatment volume
Sludge volume
Source: Agricultural Waste Handbook, USDA, 1996.
Figure 5.4.2-1. Cross-Section of an Anaerobic Lagoon
5-29
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Step 1) Determination of Lagoon Volume
The lagoon volume is determined by the following equation:
Pond Volume = Sludge Volume + Minimum Treatment Volume + Manure and Wastewater
+ Runoff + Net Precipitation + Design Storm + Freeboard
The determination of each volume is discussed below.
Sludge Volume
The amount of sludge that accumulates between lagoon cleanouts varies based on
the type and amount of animal waste. As manure decomposes in the lagoon, portions of the total
solids do not decompose. A layer of sludge accumulates on the floor of the lagoon, which is
proportional to the quantity of total solids that enter the lagoon. The sludge accumulation period
is equal to the storage retention time of the lagoon. The rate of sludge accumulation is 0.0729
fWlb solids for dairy cattle (USDA NRCS, 1996). The calculation of the separator solids is based
on a 50 percent settling rate. The calculation of the runoff solids is discussed in Section 4.7.
where:
Sludge Volume = Sludge Accumulation x (Separator Solids + Runoff Solids)
Sludge Volume
Sludge Accumulation
Separator Solids
Runoff Solids
Volume of accumulated sludge in the lagoon
between cleanouts (depends on the type and amount
of animal waste), ft3
0.0729 fWlb
Amount of solids entering the lagoon from the-
separator, Ib
Amount of solids entering the lagoon from runoff,
Ib.
5-30
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Minimum Treatment Volume (MTV)
The minimum treatment volume is the minimum volume of the lagoon to insure
anaerobic treatment for a given volatile solids loading. The minimum treatment volume is based
on the volatile solids loading rate (VSLR), which varies with regional temperature. The minimum
treatment volume is calculated using the influent daily volatile solids loading from all sources, and
a regional volatile solids loading rate per 1,000 ft3. The influent daily volatile solids loadings is
calculated using the'manure volatile solids and settling basin efficiency. The quantity of volatile
solids (VS) entering the lagoon is calculated using the following equation:
where:
Influent VS = Manure VS - (Manures VS x Settling Basin Efficiency)
Influent VS
Manure VS
Settling Basin Efficiency
Daily volatile solids loading from all sources
entering the lagoon, Ibs/day
Volatile solids excreted as part of the
manure, Ibs/day (see Technical Development
Document for manure characteristics)
0.50 (i.e., percent of solids that settled in the
settling basin).
Therefore, the minimum treatment volume is calculated as follows:
where:
MTV
Influent VS
VSLR
MTV =
Influent VS
VSLR
Minimum treatment volume (i.e., minimum volume
required for treatment to occur in the lagoon), ft3
Daily volatile solids loading from all sources
entering the lagoon, Ibs/day
Volatile solids loading rate, Ib VS/1000 ftVday.
The VSLR varies by region, as shown in Figure 5.4.2-2, because the rate of solids decomposition
in anaerobic lagoons is a function of temperature (USDA NRCS, 1996).
5-31.
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Manure and Wastewater Volume
Lagoons are designed to store manure and wastewater that is generated over a
specific period of time, typically '90 to 365 days. For all options except Option 7, the storage
period used in the cost model is 180 days.
5-32
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a1
1
5-33
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All of the manure and wastewater that is flushed or hosed from the dairy parlor or
bam is washed to a concrete settling basin (or separator) before it enters the lagoon (see Section
5.2). To calculate the influent to the lagoon over the storage .period, the daily effluent from the
separator is multiplied by the number of days of storage required. It is assumed that the barn flush
water is recycled back to the barns from the lagoon; therefore, only one storage volume of bam
flush water is added to the total influent over the whole storage period. It is assumed that the
settling basin has a 50-percent solids removal efficiency, and the removed solids have a moisture
content of 80 percent (based on best professional-judgement). The following equations are used
to calculate the influent to the lagoon: .
Lagoon Influent = (Parlor Wash + Bam Wash + Manure Water) x Storage Days
where:
Lagoon Influent
Parlor Wash
Bam Wash
Manure Water
Storage Days
Effluent from the separator entering the lagoon,
gallons, gal
Wastewater that is flushed or hosed from the parlor,
gallons per day, gpd
Wastewater that is flushed or hosed from the barn,
The portion of manure that enters the lagoon that is
not solid, gpd
Retention time of the lagoon (varies by option).
See Section 4.5 for more information regarding calculating the parlor wash and bam wash and
Section 4.6 for manure water.
Recycled Barn Water = Barn Wash * (Storage Days - 1)
where:
Recycled Barn Water =
Bam Wash =
Storage Days =
Wastewater recycled from the lagoon to use as barn
flush water, gpd
Wastewater that is flushed or hosed from the barn,
Retention time of the lagoon (varies by option).
5-34
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Lagoon Storage = [(Parlor Wash + Bam Wash + Manure Water) x Storage Days] - Recycled Barn Water
where:
Lagoon Storage =
Parlor Wash " =
Barn Wash =
Manure Water =
Storage Days -- =-
Recycled Barn Water ..=
Separator wastewater entering the lagoon for
.„_. ^storage, ga]L_
Wastewater that Is flushed or hosed from the parlor,
..' gpd r . . ...
Wastewater that is flushed or hosed from the bam,
gpd
The portion of manure that enters the lagoon that is
not solid;"gpd~
Retention time of the lagoon (varies by option).
_. Wastewater recycled from the lagoon to use as barn
flush water, gpd.
where:
Lagoon Solids = Manure Solids - (Manure Solids x Separator Efficiency)
Lagoon Solids =
Manure Solids - -—
Separator Efficiency =
Solids entering the lagoon from the separator, ft3
Manure solids entering the separator, ft3
0.50 (i.e., percent of solids that settled in the
separator).
Net Precipitation
The lagoon depth is increased to allow for the six-month precipitation minus the
six-month evaporation, as discussed in Section 4.7, The net precipitation contribution to the
lagoon depth is equal to the average precipitation minus the average evaporation.
Design Storm
The depth of the peak storm event is added to the depth of the lagoon. For all
options except Option 1A, this peak rainfall event is the 25-year, 24-hour rainfall. For Option 1 A,
a sensitivity analysis done by EPA to account for chronic rainfall, the peak storm is defined as the
25-year, 24-hour rainfall plus the 10-year, 10-day rainfall (see Section 8.0).
5-35
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Peak Precipitation = 25-year, 24-hour Rainfall or 25-year, 24-hour + 10-year, 10-day Rainfall
where:
Peak Precipitation
25-Yr, 24-Hr Rainfall
10-Yr, 10-Day Rainfall
Precipitation depth that falls directly on the
lagoon from the peak rainfall event, inches
Depth of the 25-year, 24-hour peak rainfall
(used for Option 1 through 7), inches
Depth of the 10-year, 10-day chronic rainfall
(used for Option 1A), niches.
Freeboard
A minimum of one foot of freeboard is added to the depth.
Runoff
The amount of runoff from the drylot entering the lagoon is determined from the
net precipitation and area of the drylot, as discussed in Section 4.7. The amount of runoff is
determined by estimating the precipitation for the number of days of storage assumed for each
option. New lagoons are costed under Options 1 through 6 for 180 days of storage. Option 7
storage requirements are presented in Table 5.4.2-1. In addition, the runoff contribution to the
lagoon is reduced by the amount of water retained by the solids that settle out in the basin. The
solids entering the lagoon are 1.5 percent of the total runoff from the drylot (MWPS, 1993). The
peak storm runoff is also included in the storage requirements. Section 4.7 describes the details
of the precipitation and runoff calculations.
5-36
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Table 5.4.2-1
Lagoon Storage Capacities at Dairies for Option 7
Region
Central
Mid-Atlantic
Midwest
Pacific
South
Estimated Storage-
Capacity for
Option 7 (days)
180
225
225
135
45
Estimated Existing
Storage Capacity
(days)
60 .
30
90
30
30
Additional Lagoon
Capac% Costed !br ; v
Existing Ponds (days) ; r
120
195
135
105
where:
Influent Runoff Solids^^ = Runoff^^ x % Runoff Solids
Influent Runoff Solids,
Run°ff6-month
% Runoff Solids
'6-month
Amount of solids entering the lagoon from
the drylot (i.e., solids exiting the settling
basin), ft3
Amount of the total runoff entering the
lagoon from the drylot, ft3
1.5% (i.e., the percent of runoff entering the
lagoon that consists of solids).
Step 2) Dimensions and Configuration of the Lagoon
The lagoon is designed in the shape of an inverted pyramid with a flat bottom,
containing the required volume. The depth of the lagoon is set as follows:
where:
h = Initial Depth + Net Precipitation + Freeboard
h = Depth of the lagoon, ft
Initial Depth = 10 ft
5-37
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Net Precipitation
Freeboard
Six-month precipitation depth that falls directly on
the pond minus the amount that evaporates from the
pond, ft
1ft.
For dairies and veal operations, the initial depth of the lagoon is set at 10 feet,
based on discussions with industry consultants. This initial depth is assumed to include depth for
the runoff and solids. This depth is used as the starting value for the dimensions calculations
using the required volume of the lagoon. The lagoon is assumed to be square, and the final depth
and length is solved by iteration, knowing the lagoon volume and the other variables in the
equation. ' r ••
Lagoon Excavation and Embankment Volumes
Lagoons are constructed by excavating a portion of the necessary volume and
building embankments around the perimeter of the lagoon to make up the total design volume.
The cost model performs an iteration to maximize the use of excavated material used in
itructing the embankments that minimizes the costs for construction. The excavation volume
cons'
is represented by the following equation:
where:
W
= C, (h-he) [lbwb + lsws + (lbwblswsH
Total volume of soil extracted from the lagoon, ft3
constant equaling Yz for dairy cost model
Depth of the lagoon, ft
Height of embankment, ft
Length of the base of the lagoon, ft
Width of the base of the lagoon, ft
Length of the top of the lagoon, ft
Width of the top of the lagoon, ft.
The excavated soil is used to build the embankments. Because some settling of the soil will
occur, it is assumed that an extra 5 percent of volume is required. The embankment volume is
represented by the following equation:
5-38
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Vplumeembankmcnt = 2 [(1.05 hcwe + s (1.05 h,)2) (lb +2 sh)] + 2 [(1.05 hewe + (1.05 s)2 he2) (w + 2sh)]
where:
Volumeembankment Total volume of soil used for the embankment, ft3
he = Height of embankment, ft
we -.=.-' Width of embankment, ft
= Length of the base of the lagoon, ft
= Slope of sidewalls
= Width of the floor of lagoon.
S
W
The dimensions of the basin which yield the desired volume are calculated by the cost model using
these equations.
i' ' „. - • • r- • ,...'. 1 -
" ' ' ' ' t-\ r ' * '• •
Lagoon Liners
For Options 3A/3B and 3C/3D, lagoons are designed with a synthetic liner for
those operations located in areas requiring ground water protection. The costs assume that clay is
brought on site in a truck (locally) and applied as a slurry to the lagoon.basin. The liner system
consists of clay soil with a synthetic liner cover. The dimensions are equal to the surface area of
the floor and sides of the lagoon.
The surface area of the floor of the lagoon is calculated to determine the area for
compaction and for the lagoonliner. The surface area includes the bottom area plus the area of
the four trapezoids that make up the sides of the lagoon.
a trapezoid.
The surface area of the sloped sides is calculated using the formula for the area of
Area of Side, = '/2 HS x (lb + is)
Area of Sidew = 1A HS x (Wb + wj
5-39
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where:
Area of Side,
Area of Sidew
HS
w
, Area of length side of the lagoon, fi2
Area of width side of the lagoon, ft2
u,. ^Height of the side on file lagoon (see equation below), ft
Bottom length of the lagoon, ft
Top length of the lagoon, ft
Bottom width of the lagoon; it — '-
-Top width of the lagoonr.ft. - -
The height of the side is'calculated using the Pythagorean Theorem.
where:
HS =
h
(4h)2)°
Height of the side on the lagoon, ft
Depth of the lagoon, ft.
The total surface area of the basin is:
where:
Surface Area,MOOn = lb Wb + 2 [Area of Side,] + 2 [Area of Si'deJ
Surface Arealagoon
!„
wb
Area of Side,
Area of Sidew
Total surface area of the pond floor, including the
bottom and sides, ft2
Bottom length of the pond, ft
Bottom width of the pond, ft
Area of length side of the pond, ft2
Area of width side of the pond, ft2.
5.4.3
Costs for Constructing a Dairy Lagoon
The construction of the storage lagoon includes a mobilization fee for the heavy
machinery, excavation of the lagoon area, compaction of the ground and walls of the lagoon, and
the construction of conveyances to direct runoff from the drylot area to the storage lagoon. Table
5.4.3-1 presents the unit costs used to calculate the capital and annual cost for constructing the
storage lagoon.
5-40
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Table 5.4.3-1
Unit Costs for Storage Lagoon
Unit
Mobilization
Excavation
Compaction
Flush Wash Conveyance ,
Hose Wash Conveyance
Clay Liner (shipped & installed)
Synthetic Liner (installed)
information takftn frnm N/fpnnb fonts*
1
-Cost"*"^ ' :
(1997 dollars)
$205/event
$2.02/yd3
$0.41/yd3
$ll,025/system
$7,644/system
$0.24/ft2
$1.50/ft2
=======================^==========,
Source
Means 1999 (022 274 0020)a
Means 1 999 (022 238 0200)a
Means 1996 (022 226 :5720)a
ERG, 2000c.
ERG,2000c ...
AEA, 1999
Tetra Tech, 200Qc
numbers.
The calculations for the cost associated with these items are shown below.
Mobilization
The mobilization costs are for transporting the heavy machinery and equipment.
The Means Construction Data reports that this cost is $205/event.
Excavation
To calculate the lagoon excavation costs, the volume of material that is excavated
is first calculated, as described previously. The excavated material is expected to be used to
construct embankments around the lagoon, which will provide additional storage other than that
volume which is excavated; therefore, the excavated volume is not equal to the lagoon volume.
Instead, it is equal to the pond volume minus the storage that the embankments provide.
The excavation cost is calculated with the following equation:
Excavation = Cost x Volumeexcaval=d - Conversion Factor
5-41
-------
where:
Excavation
Cost
Conversion Factor =
Total cost to excavate the lagoon, $
$2.02/yd3 (i.e., cost per the volume of soil
excavated)
Amount (volume) of soil excavated, ft3
27 ft3/yd3 (conversion from ft3 to yd3).
Compaction
To calculate compaction costs, the volume for compaction is calculated, as
described in Section 5.1.3. The compaction cost is calculated using the following equation:
where:
Compaction = Cost x Volumecompacled (ft3) - Conversion Factor
Compaction
Cost
Conversion Factor =
Total cost to compact the lagoon, $
$0.41/yd3 (i.e., cost per volume of soil compacted)
Amount (volume) of soil compacted, ft3
27 ftVyd3 (conversion from ft3 to yd3).
Conveyance
The conveyance costs are for constructing conveyances to direct runoff from the
drylot area to the lagoon. According to the Means Construction Data, this cost is $11,025/system
for flush wash conveyance and $7,644/system for hose wash conveyance.
Clay and Synthetic Liners
To calculate liner costs, the surface area of the basin flow and sidewalls is
calculated, as described previously. The liner cost includes both clay and synthetic liners, and is
calculated using the following equations:
5-42
-------
where:
Glay Liner
Cost
Surface Area
Clay Liner = Cost x Surface Area
,C6st to install a clay liner, $
$Q.24/ft? (i.e., post per the surface area of the pond)
Surface area of the basin floor and the sidewalls, ft2.
where:
Synthetic Liner
Cost
Surface Area
Synthetic Liner = Cost x Surface Area
<-Cost to install a synthetic liner, $
$1.SO/ft2 (i.e., cost per the surface area of the pond)
Surface area of the basin floor and the sidewalls, ft2.
following:
following:
Total Capital Costs
The total capital cost for construction of the naturally lined storage lagoon is the
Capital Cost = Mobilization + Excavation + Compaction + Conveyance
The total capital cost for construction of the synthetically lined lagoon is the
Capital Cost = Mobilization + Excavation + Compaction + Conveyance +
Clay Liner + Synthetic Liner
Total Annual Costs
Based on best professional judgement, annual operating and maintenance costs for
both naturally lined and synthetically lined lagoons are estimated at 5 percent of the capital costs.
Annual Cost = 5% x Capital Cost
5-43
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5.4.4
Dairy Lagoon Results
The cost model results for constructing a naturally lined lagoon, a synthetically
lined lagoon, and additional lagoons'for extra capacity (Option 7) at dairies are presented in
Appendix A, Table A-4, Table A-5 ,- and Tables A-6a and 6b, respectively.
5.4.5
Design of Lagoons and Evaporative Ponds for Swine and Poultry Operations
Basic volume requirements, for liquid storage are determined by calculating the
manure volume generated for the storage period and multiplying that number, by-a dilution factor.
The dilution factor is intended to address process dilution; netdifect precipitation (precipitation
minus evaporation over lagoon surface), freeboard (1 foot), and storage for the 25-year, 24-hour
rainfall event.
Design
The basic design steps employed for dairy and veal lagoons are also used for swine
and poultry lagoons. Unique lagoon dimensions are calculated for each model facility based upon
the required storage volume. The cost model applies berms on two sides of liquid storage
structures to eliminate runoff into storage facilities (see Section 5.3).
USDA's design approach provides storage for manure, clean water used in
dilution, accumulated solids and wastewater, net precipitation (precipitation - evaporation), the
25-year 24-hour rainfall event, and 1 foot of freeboard (USDA NRCS, 1996). In cases where
there are watersheds draining to the lagoon, USDA adds volume for runoff. Basic volume
requirements for storage of liquid wastes from swine and wet layer operations are determined by
calculating the manure volume generated for the storage period and multiplying that number by a
dilution factor. The dilution factor is intended to address process dilution, net direct precipitation
(precipitation minus evaporation over lagoon surface), freeboard (1 foot), and storage for the 25-
year 24-hour rainfall event. Solids accumulation is assumed to not occur since it is assumed that
waste is agitated and mixed before application to fields.
5-44
-------
The suitability of the modeled lagoons to handle all inputs was tested in an exercise
to determine if overflows would occur due to chronic and 25-year, 24-hour rainfall events. No
capacity problems were found in this testing, so it is concluded that lagoons designed using the
cost model approach are reasonable approximations of .those designed using USDA's approach.
The storage period for lagoons is assumed to be six months, except for those
options and scenarios where storage is increased. The required storage volume (Volumestorage) is
therefore calculated as:
where:
Volume,,
dilution
•2
Volumeslorage = Volumemimiirc x dilution/2
annual volume of manure produced
dilution factor (ranges from 1 to 3)
12 months/6 months storage.
The cost model addresses five cases for which lagoon construction costs are
included: (1) Option 1A, where increased storage is provided to handle chronic rainfall events at
wet layer operations and at swine operations with liquid or evaporative pond systems, (2)
increased storage for all swine facilities under Option 7, (3) the construction of secondary lagoons
for settling as part of the installation of flush-water recycling systems for Category 2 liquid swine
facilities under all options other than Option 5, (4) the replacement of evaporative ponds with
lined and covered lagoons under Option 5, and (5) the construction of a secondary lagoon with
storage for 20 days in conjunction with liner installation for liquid and evaporative pond systems.
In all other cases, the storage facility is designed for the purpose of deriving costs for liners,
covers, and diversions only, and lagoon construction costs are not included.
Under Option 1 A, the storage volume is increased to handle chronic rainfall,
ranging from 5 to 11 inches (see Table 5.4.5-1). The extra lagoon for flush-water recycling
systems is designed to handle storage for 20 days, the same design volume used for extra lagoons
constructed when liners are added to existing lagoons and evaporative ponds. Increased storage
under Option 7 is set to 90 days for the Mid-Atlantic region and 135 days for the Midwest and
5-45
-------
Central regions. Lagoons constructed to replace evaporative ponds are designed to handle the
same volume as the evaporative ponds, and then 6 inches of depth is removed to account for the
covers which keep direct precipitation from entering the lagoon.
Table 5.4.5-1
Chronic Rainfall Amounts for Option 1A for Swine and Poultry
Region
Central
Mid-Atlantic
Midwest
South
Chronic Rainfall Amount (inches)
5
11
' ' ' ' ' 7
10
Dimensions and Configuration
The shape assumed for lagoons and evaporative ponds is an upside-down frustrum,
which is a pyramid with the top chopped off. The shape and parameters of a frustrum are given in
Figure 5.4.5-1. The cost model assume that lagoons and evaporative ponds are square (a=b and
c=d).
Area and Volume of the Frustrum of a Pyramid
Area ~ &i •*- B2-f A*
= ab + cd +(a+b-H:-HJ) »
Votume = --h (B,
Figure 5.4.5-1. Frustrum
5-46
-------
Because lagoons have sloping sides, the minimum volume associated with a lagoon
12 feet deep with side slopes (H:V) of 2 is 9,216 cubic feet. For an evaporative pond with a
depth of 4 feet and side slopes of 2, the minimum volume is 341 cubic feet. Since the cost model
calculates lagoon dimensions from lagoon volume, which can be very small for secondary
lagoons, there is the potential that calculations result in negative bottom widths and lengths if the
depth and side slopes are fixed values. To prevent these negative values from occurring, an
analysis of lagoon dimensions resulting from various volumes, lagoon depths, and side slopes was
conducted. The results from this, analysis are presented in Table 5.4.5-2. When applying the
information contained in Table 5.4.5-2 to the design of anaerobic lagoons in the cost model, the
default depth is 12 feet, and a preference is given to maintaining a depth of at least 10 feet
wherever possible, but no less than 6 feet (see Table 5.4.5-3). This approach is consistent with
USDA guidelines specifying that the minimum acceptable depth for anaerobic lagoons is 6 feet,
but in colder climates at least 10 feet is recommended to assure proper operation and odor control
(USDA NRCS, 1996). USDA also recommends that internal slopes be no less than 1.5:1 (H:V)
for liquid storage (USDANRCS; 1996).
According to the American Society of Agricultural Engineers standards (ASAE,
1998), a minimum lagoon depth of 5 feet is necessary for construction of anaerobic lagoons, and
approximately 20 feet is considered the maximum depth to ensure proper biological activity.
5-47
-------
table 5.4.5-2
Relationships Among Depth, Side Slope, Volume, And
Bottom Width of Lagoons
Depth
12
12
12
11
11
11
10
10
10
9
9
9
8
8
8
7
7
7
6
6
6
6
5
5
5
5
4
4
4
4
Side Slope
4
3
2
4
3
2
4
3
2
4
3
2
4
3
2
4
3
2
4
3
2
1
4
3
2
1
4
3
2
1
Volume Below Which Calculations Result In
Negative Value for Bottom Width of Lagoon
36,864
20,736
9,216
28,395
15,972
7,099
21,334
12,000
5,334
15,552
8,748
3,888
10,923
6,144
2,731
7,318
4,116
1,830
4,608
2,592
1,152
288
2,667
1,500
667
167
1,365
,768
342
86
5-48
-------
Table 5.4.5-3
Depth and Side Slopes for Lagoons and Evaporative Ponds
Volume (cubic feet)
> 0 and < 342
>=342
>0and<167
>=167and<288 '
>=288 and <1,152
>=l,152and=l,830and<2,731
>=2,731and<3,888
>=3,888 and <5,334
>=5,334 and <7,099
>=7,099and<9,216
>=9,216
Lagoons
Depth
NA
NA
4
5
6
6
7
.8
r 9
10 '
11
12
Slope
.NA
NA
1
1
1
2
2
2
2
-' 2
2
2
Evaporative Ponds
Depth
, '4
4
NA
' NA
NA
NA
NA
NA :
NA
NA
NA
NA
Slope
1
2
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA: Not applicable. , . •
Because some of the modeled lagoons are very small, a depth of 4 feet is allowed for volumes less
than 167 cubic feet, and a depth of 5 feet is allowed for volumes of 167-287 cubic feet. This
allowance for shallow anaerobic lagoons is particularly important in calculations of the costs for
extra storage.
Lagoon dimensions are calculated from volume using the following basic
equations:
Wlagoonbottom=[(-2h2s)+((4x(h^) x (s2)) - 4xhx((4/3)x(h3)x(s2).Volumestorage))°-5]-f-2h
=
•^lagoonbottom ** lagoonbottom
Wlagoontop =Wlagoonbottom+(2 X S X depth)
Llagoomop=Liagoonbottom+(2 x S X depth)
5-49
-------
where:
"lagoonbottom
w
•'lagoontop
•Magoonbottom
•Magoontop
S
h
Width of bottom of lagoon or evaporative pond, ft
Width of top of lagoon or evaporative pond, ft
Length of bottom of lagoon or evaporative pond, ft
Length of top of lagoon or evaporative pond, ft
Slope of sidewalls
Depth of the lagoon, ft.
To simulate increased storage volume for chronic rainfall under Option 1 A, the
cost model increases the top width (and length since it is assumed to be square) of the lagoon with
the following equation:
where:
W,
' * lagoontop
S
chronic
12
2
Wlagoontop =WIagoontop + (2 x s x chronic •*-12)
Width of top of lagoon or evaporative pond, ft
Slope of sidewalls
Chronic rainfall, in
12 inches per foot
Two sides.
The equation essentially builds additional storage above the existing lagoon,
resulting in a wider, longer, and deeper lagoon. The new top width and length are used to
calculate the new lagoon volumes, liner areas, berm dimensions, and cover areas for Option 1 A.
The increase in lagoon volume is calculated by subtracting the original volume from the new
volume.
An additional 20 days of storage is provided by both the extra lagoons for flush-
water recycling systems and the extra lagoons constructed when liners are added to existing
lagoons and evaporative ponds. This additional storage volume (Volume20.daystorage) is calculated
with the following equation:
, * 20 - 365 - 7.481 - 27
5-50
-------
where:
= 12-month storage volume in gallons
20/365 = Fraction of year covered by 20 days
7.481 converts to cubic feet - . • . .
27 converts to cubic yards.
Increased storage under Option 7 is set to 90 days for the Mid-Atlantic region and
135 days for the Midwest and Central regions. The storage volume is calculated using the same
equation as above, with the exception that 20 is replaced with 90 or 135.
Under Option 5, the cost model builds a new lago'on to replace evaporative ponds
since this approach is less expensive than covering the large but shallow evaporative ponds. First,
the dimensions of the new lagoon are determined using the basic equations from above. Then,
lagoon depth is decreased by 6 inches. The typical annual rainfall in the central region where
evaporative ponds are used is 1 foot, and 6 inches is selected since the storage period is six
months. The lagoon bottom width and length remain the same, but the width and length of the
lagoon top are then recalculated using the following equations:
where:
W,
' * lagoontop
•Magoontop
S
"lagoontop "lagoontop ~ (2 X S)
*-'lagoontop~~Magoontop ~ (2 x S)
Width of top of lagoon or evaporative pond, ft
Length of top of lagoon or evaporative pond, ft
Slope of sidewalls.
Volume is then calculated using the frustrum equation with the original bottom dimensions, the
new depth, and the new top dimensions.
5-51
-------
Lagoon Liners
The surface area of lagoons and evaporative ponds for swine and poultry
operations is calculated using the same basic equations described in Section 5.4.2 for dairies and
veal operations. The cost for a lagoon is calculated using the same costs shown in Table 5.4.3-1.
5.4.6
Costs for Lagoons at Swine and Poultry Operations
Capital Costs
The excavation cost of $2.60 per cubic yard for swine and poultry operations is
multiplied by the volume or volume change (e.g., Option 1 A) to determine total excavation costs.
When a liner is present, unit liner costs are the same as shown in Table 5.4.3-1, and are multiplied
by liner area to determine total liner cost.
where:
Capital Cost = Excavation Cost x Volume Excavated + Liner Cost
Excavation Cost =
Volume Excavated =
Liner Cost =
$2.60 per cubic yard
Volume or volume change of lagoon
Clay liner + synthetic liner.
capital costs.
Annual Costs
The annual maintenance and operation cost is assumed to be 2 percent of the
Annual Cost = 2% x Capital Cost
5-52
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5.5
Ponds
Waste storage ponds are frequently used at animal feeding operations to contain
wastewater and runoff from contaminated areas. Manure and runoff are routed to the storage
pond where the mixture is held until it can be used for irrigation or can be transported elsewhere.
Solids settle to the bottom of the pond as sludge, which is periodically removed and land applied
on site or off site. The liquid can be applied to cropland as fertilizer/irrigation, used for dust
control, reused as flush water for animal bams, or transported off site. Section 5.9 discusses the
costs associated with transporting waste off site, including the solids and liquids.
Ponds are included in all regulatory options for beef feedlots, heifer operations,
and as a holding pond for effluent from an anaerobic digester in Option 6. Options 1, 2, 4, 5A,
and 6 require zero discharge of manure, litter, or process wastewater pollutants from the
production area with the exception of overflows from a facility designed to hold all process
wastewater, including the direct precipitation and runoff from a 25-year, 24-hour rainfall event.
CAFOs that already have storage ponds in place are assumed to have sufficient capacity. CAFOs
that have no storage on site are costed for the installation of naturally lined ponds with 180 days
of storage. Under Option 7, CAFOs are costed for the installation of naturally lined ponds with a
storage capacity that varies based on land application timing restrictions. For Options 3A/3B and
3C/3D, CAFOs expected to have a direct hydrologic connection from ground water to surface
water are given costs for the installation of storage ponds with a liner to prevent seepage of
wastewater into ground water.
5.5.1
Technology Description
Storage ponds provide a location for long-term storage of water and are
appropriate for the collection of runoff. Ponds are typically located at a lower elevation than the
animal pens or barns; gravity is used to transport the waste to the pond, which minimizes labor.
Although ponds are an effective means of storing waste, no treatment is provided. Because ponds
are open to the air, odor can be a problem.
5-53
-------
Although ponds are not designed for treatment, there is some reduction of nitrogen
and phosphorus in the liquid effluent due to settling and volatilization. Influent phosphorus settles
to the bottom of the pond and is removed with the sludge. Influent nitrogen is reduced through
volatilization to ammonia. Pond effluent can be applied to cropland as fertilizer/irrigation, reused
as flush water for the animal barns, or transported off site.. The sludge can also be land applied as
a fertilizer and soil amendment
Storage ponds are appropriate for use at operations that collect runoff and do not
collect process water or manure flush water. Typically, beef feedlots and heifer operations
operate in this manner and have storage ponds for runoff collection. All cost options for beef
feedlots and heifer operations include a storage pond. Dairies and veal operations typically
operate lagoons (discussed in Section 5.4) to provide treatment for the barn and milking parlor
flush water; however, a storage pond is included in the costs for large dairies under Option ,6,
where the pond receives effluent from an anaerobic digester.
Not all beef feedlots and heifer operations are expected to have liquid storage
currently in place. In addition, ponds without a synthetic or clay liner are currently more
prevalent at beef feedlots and heifer operations than are lined ponds. Section 6.0 provides EPA's
estimates of the percentage of beef feedlots and heifer operations that are costed for the
installation of a pond, a pond with a liner (for Options 3A/3B and 3C/3D), or a pond with
additional capacity (for Option 7).
5.5.2
Design
The cost model assumes only direct precipitation or runoff that has gone through a
settling basin (or separator) enters the storage pond. Runoff will contain a portion of manure
solids from the beef drylots. Ponds are typically constructed by excavating a pit and using the
excavated soil to build embankments around the perimeter. An additional 5 percent is added to
the required height of the embankments to allow for settling. The sides of the pond are sloped
with a 1.5:1 or 3:1 (horizontal:vertical) ratio.
5-54
-------
Considerations are also made to avoid ground-water and soil contamination.
Options 1,2,4, 5 A, 6, and 7 assume the bottom and sides of the pond are constructed of soil that
is at least 10 percent clay compacted with a sheepsfoot roller. Under Options 3A/3B and 3C/3D,
>
some CAFOs will require additional ground-water protection; therefore, a synthetic liner is
included in the lagoon costs in addition to a compacted clay liner.
Storage ponds are designed using the following steps:
1) Determine the necessary pond volume. Storage ponds are designed to
contain the following volumes (see Figure 5.5.2-1):
— Sludge Volume: Volume of accumulated sludge between clean-outs
(depends on the type and amount of animal waste),
— • • Runoff: The runoff from drylots for normal and peak precipitation,
— Net Precipitation: Annual precipitation minus the annual
evaporation,
— Design Storm: The depth of the peak (e.g., 25-year, 24-hour)
rainfall event, and
— Freeboard: A minimum of 1 foot of freeboard.
2) Determine the dimensions and configuration of the pond, depending on the
regulatory option.
3) Determine the costs for constructing the pond, using the dimensions
calculated in Step 2.
5-55
-------
A
Freeboard
Required
volume
Depth of runoff from a 25-year, 24-hour storm event
Depth of normal precipitation less evaporation
\
Runoff from normal precipitation
Sludge volume
y
Source: Agricultural Waste Handbook, USD A, 1996.
Figure 5.5.2-1. Cross-Section of a Storage Pond
Step 1) Determination of Pond Volume
The pond volume is determined by the following equation:
Pond Volume = Sludge Volume + Runoff + Net Precipitation + Design Storm + Freeboard
The determination of each volume is discussed below.
Sludge Volume
The amount of sludge that accumulates between pond cleanouts varies based on
the type and amount of animal waste. As manure decomposes in the pond, portions of the total
solids do not decompose. A layer of sludge accumulates on the floor of the pond, which is
proportional to the quantity of total solids that enter the pond. The sludge accumulation period is
equal to the storage retention time of the pond. A rate of sludge accumulation is not available for
beef cattle but is estimated to be the same as dairy cattle: 0.0729 cubic feet per pound (ftVlb)
(USDA NRCS, 1996). The calculation of the separator solids is discussed in Section 5.2,
assuming 50-percent settling rate. The calculation of the runoff solids is discussed in Section 4.7.
5-56
-------
Sludge Volume = Sludge Accumulation x Runoff Solids
where:
Sludge Volume =
Sludge Accumulation =
Runoff Solids
Amount of sludge that accumulates between pond
cleanouts, ft3
0.0729, ftMb
Quantity of total solids that enter the pond following
separation, pounds, Ib.
Runoff
The amount of runoff entering the pond is determined from the net precipitation
and area of the drylot, as discussed in Section 4.7. The amount of runoff is determined by
estimating the precipitation for the number of days of storage assumed for each option. New
ponds are costed under Options 1 through 6 for 180 days of storage. Option 7 storage
requirements are presented in Table 5.5.2-1. In addition, the runoff contribution to the pond is
reduced by the amount of water retained by the solids that settle out in the basin. The solids
entering the earthen basin are 1.5 percent of the total runoff (see Section 4.7 for more
information), while the solids entering the pond are 50 percent of the basin solids (i.e., the
efficiency of the settling basin is assumed to be 50 percent).
Table 5.5.2-1
Pond Storage Capacities at Beef Feedlot and Heifer Operations for Option 7
'v ' Region
Central
Mid-Atlantic
Midwest
Pacific
South
Estimated Storage
Capacity for
Option 7 (days)
180
225
225
135
45
Source: ERG, 2000a and ERG 2002.
Estimated Existing
Storage Capacity
,/ . ' (days)
50
80
190
30
45
'
Additional Pond
Capacity Costed for ••
Existing Ponds (days)
130
145
35
105
0
'
5-57
-------
Influent Runoff Solids,^,,,,,, = Total Runoff Solids6.roomh x (l^Settling Basin Efficiency)
where:
Influent Runoff Solids
Total Runoff Solids6.momh
Settling Basin Efficiency
Amount of solids entering the pond (i.e.,
solids exiting the settling basin), ft3
Amount of the total runoff entering the
settling basin that consists of solids, ft3
50% (i.e., percent of solids that settled in the
settling basin).
where:
Note that:
Settled Solids6.monlh = Total Runoff Solids^™,,, x Settling Basin Efficiency
Settled
Total Runoff Solids^,,,
Settling Basin Efficiency
Amount of solids that settled in the settling
basin from the runoff entering the basin, ft3
Amount of the total runoff entering the
settling basin that consists of solids, ft3
50% (i.e., percent of solids that settled in the
settling basin).
Total Runoff Solidss.^,,, = Influent Runoff Solids6.raonth + Settled Solids^,,,,,,,
For the cost model calculations, it is assumed that settled solids have a moisture
content of 80 percent (based on best professional judgement); therefore, the runoff entering the
pond is:
180 days
x Storage Days -
where:
Settled Solids6.month x Solidsmoisture
1 Solidsmoisture
+ Peak Rainfall Runoff
Amount of runoff entering the pond from the
settling basin and drainage area, ft3
Total runoff entering the settling basin calculated
using the average monthly precipitation amounts
from the wettest six-month consecutive period (see
Section 4.7), ft3
5-58
-------
180 days
Storage Days
Settled Solids,
'6-month
Solids,
moisture
Peak Rainfall Runoff =
Number of storage days for runoff
Required number of storage days for the specific
option, days
Amount of solids that settled in the settling basin
from the runoff entering the basin, ft3
80% (i.e., moisture content percentage in the settled
solids)
Total runoff from the peak rainfall event (either 25-
year, 24-hour or 25-year, 24-hour plus 10-year, 10-
day).
Section 4.7 describes the details of the precipitation and runoff calculations.
Net Precipitation , , .,
The. pond depth is increased to allow for direct net precipitation, as discussed in
Section 4.7. The net precipitation contribution to the pond depth is equal to the average
precipitation minus the average evaporation.
Design Storm
The depth of the peak rainfall event is added to the depth of the pond to account
for direct precipitation. For all options except 1 A, this peak rainfall event is the 25-year, 24-hour
rainfall. For Option 1 A, a sensitivity analysis conducted by EPA to account for chronic rainfall,
the peak storm is defined as the 25-year, 24-hour rainfall plus the 10-year, 10-day rainfall.
Precipitation information for these storms was also extracted from the NCDC database.
where:
Peak Precipitation =25-Yr, 24-Hr Rainfall or 25-Yr, 24-Hr + 10-Yr, 10-Day Rainfall
Peak Precipitation
25-Yr, 24-Hr Rainfall
10-Yr, 10-Day Rainfall
Precipitation depth that falls directly on the
pond from the peak rainfall event, inches
Depth of the 25-year, 24-hour peak rainfall,
inches
Depth of the 10-year, 10-day chronic rainfall',
inches.
5-59
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Freeboard
A minimum of 1 foot of freeboard is added to the depth.
Step 2) Dimensions and Configuration of Pond
The pond is designed approximately in the shape of an inverted frustum (i.e., an
inverted pyramid with a flat bottom), containing the required volume. The initial depth of the
pond is set as follows:
•h = Initial Depth + Net Precipitation + Freeboard + Peak Precipitation
where:
Initial Depth.
Net Precipitation
Freeboard
Peak Precipitation
Depth of the pond, ft
10ft
Six-month precipitation depth that falls directly on
the pond minus the amount that evaporates from the
pond, ft
1 foot
Precipitation depth that falls directly on the pond
from the peak rainfall event, ft.
The initial depth of the pond is set at 10 feet, based on discussions with industry
consultants. This initial depth is assumed to include depth for the runoff and solids. This depth is
used as the starting value for the dimensions calculations using the required volume of the pond.
The pond is assumed to be square,- and the final depth and length is solved by iteration, knowing
the pond volume and the other variables in .the equation.
Fond Dimensions
For the cost model calculations, it is assumed that the pond has four sloped sides
with a rectangular base. To determine the dimensions of the pond, the design volume of the pond
is used with the design parameters discussed previously. The following equation is used to
determine the length of the basin:
5-60
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where:
Pond Volume = Vz h [A, + A2 + (A, A2 )°-5]
Pond Volume = 1A h [lb Wb + ls Ws +• (lbWblsWs)0-5]
Pond Volume
h
A,
A2
Wb
Is
w,
Necessary volume of the pond calculated in Step 1), ft3
Depth of the pond, ft
Area of the bottom base of the pond, assuming the pond is
square (this equals lb Wb)
Area of the top (surface area) of the pond, assuming the
ixmd is square (this equals ls Ws)
Length of the base of the pond, ft
Width of the base of the pond, ft
Length of the top of the pond, ft
Width of the top of the pond, ft.
Pond Excavation and Embankment Volumes
Ponds are constructed by excavating a portion of the necessary volume and
building embankments around the perimeter of the pond to make up the total design volume. The
cost model performs an iteration to maximize the use of excavated material used in constructing
the embankments that minimizes the costs for construction. The excavation volume is
represented by the following equation: ' '
where:
Volumeexoavated = 0.5 (h-hc) [lbwb + lsws
Volume,
'excavated
W
Total volume of soil extracted from the pond, ft3
Depth of the pond, ft
Height of embankment, ft
Length of the base of the pond, ft
Width of the base of the pond, ft
Length of the top of the pond, ft
Width of the top of the pond, ft.
The excavated soil is used to build the embankments. Because some settling of the
soil will occur, it is assumed that an extra 5 percent of volume is required. The embankment
volume is represented by the following equation:
-------
Volun«w«ta«i = 2 [(1.05 hcwe + s (1.05 he)2) (lb +2 sh)] + 2 [(1.05 hewe + (1.05 s)2 he2) (w + 2sh)]
where:
S
W
Total volume of soil used for the embankment, ft3
Depth embankment, ft
Width embankment, ft
Length of the base of the pond, ft
slope of walls of pond, ft/ft
width of the base of the pond, ft.
The dimensions of the basin which yield the desired volume are calculated by the cost model.
Pond Liners
For Options 3A/3B and 3C/3D, ponds,are designed with a synthetic liner for those
operations located in areas requiring ground water protection. The liner consists of clay soil with
a synthetic liner cover. The dimensions of the liner are equal to the surface area of the floor and
sides of the pond.
The surface area of the floor of the pond is calculated to determine the area for
*
compaction and for the pond liner. The surface area includes the bottom area plus the area of the
four trapezoids that make up the sides of the pond.
The surface area of the sloped sides is calculated using the formula for the area of
a trapezoid.
where:
Area of Side, =
AreaofSidew =
HS
Area of Side, = K HS * (lb + ls)
Area of Sidew = 1A HS x (wb + ws)
Area of length side of the pond, ft2
Area of width side of the pond, ft2
Height of the side on the pond (see equation below), ft
Bottom length of the pond, ft
Top length of the pond, ft
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w
Bottom width of the pond, ft
Top width of the pond, ft.
The height of the side is calculated using the Pythagorean Theorem.
20-5
where:
HS. ='
h =
(4h)2)
Height of the side on the pond, ft
Depth of the pond, ft.
The total surface area of the basin is:
where:
Surface Area,,ond = lb Wb + 2 [Area of Side,] + 2 [Area of Sidew]
Surface Areap0[ld
wb
Area of Side,
Area of Side,,
Total surface area of the pond floor, including the
bottom 'and sides, ft2
Bottom length of the pond, ft
Bottom width of the pond, ft
Area of length side of the pond, ft2
Area of width side of the pond, ft2.
5.5.3
Costs
The construction of the storage pond includes a mobilization fee for the heavy
machinery, excavation of the pond area, compaction of the ground and walls of the pond, and the
construction of conveyances to direct runoff from the drylot area to the storage pond. Table
5.5.3-1 presents the unit costs used to calculate the capital and annual cost for constructing
storage ponds.
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Table 5.5.3-1
Unit Costs for Storage Pond
Unit
Mobilization
Excavation
Compaction
Conveyance
Clay Liner (shipped & installed)
Synthetic Liner (installed)
Cost
(1997 dollars) .
$205/event
$2.02/yd3
$0.4J/yd3
$7,644/event
• $Q.2A/& — •
••$r.5o7ft2""' ' :
v • ' Source
Means 1999 (022 274 0020)"
Means 1999 (022 238 0200)"
Means 1996 (022 226 5720)a ,
ERG,2000c
AEA;--1 999 ! '•
f etra Tech, 2000c
The calculations for the costs associated with these items are shown below:
Mobilization
, • 1
The mobilization costs are $205/event (i.e., $205 to mobilize all equipment on
site). These costs are for moving the appropriate heavy machinery and equipment.
Excavation
To calculate the pond excavation costs, the volume of material that is excavated is
first calculated, as described previously. The excavated material is expected to be used to
construct embankments around the pond, which will provide additional storage other than that
volume which is excavated; therefore, the excavated volume is not equal to the pond volume.
Instead, it is equal to the pond volume minus the storage that the embankments provide.
The excavation cost is calculated with the following equation:
Excavation = Cost x
Volumeexcavated
Conversion Factor
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where:
Excavation
Cost
Volumeexcavated
Conversion Factor
Total cost to excavate the pond, $
$2.02/yd3 (i.e., cost per the volume of soil
, _ excavated)
Amount (volume) of soil excavated, ft3
27 ftVyd3 (i.e., conversion from ft3 to yd3).
Compaction
> " ~*'
To calculate compaction costs, the volume for compaction is calculated, as
described in Section 5.1. The compaction cost is calculated with the following equation:
where:
Compaction = Cost x
Volume,
'compacted
(ft3)
Compaction
Cost
Volumecompacted
Conversion Factor
Conversion Factor
Total cost to compact the pond, $
$0.41/yd3 (i.e.', cost per volume of soil compacted)
Amount (volume) of soil compacted, ft3
27 fWyd3 (i.e., conversion from ft3 to yd3).
Conveyance
The conveyance costs are for constructing conveyances to direct runoff from the
drylot area to the storage pond. According to the Means Construction Data, this cost is
$7,644/event.
Clay and Synthetic Liners
To calculate liner costs, the surface area of the basin'floor and sidewalls is
calculated, as described in Section 5.1. The liner cost includes both a clay and synthetic liner, and
is calculated using the following equations:
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where:
Clay Liner =
Cost
Surface Area =
Clay Liner = Cost x Surface Area
Cost to install a clay liner, $
$"0.24/ft? (i.e., cost per the surface area of the pond)
Surface area of the basin floor and the sidewalls, ft2.
where:
Synthetic Liner = Cost x Surface Area
Synthetic Liner
Cost
Surface Area
Cost to install a synthetic liner, $
$l.5Q/fP(i.e., cost per the surface area of the pond)
Surface area of the basin floor and the sidewaills, ft2.
following:
following:
Total Capital Costs for Naturally Lined and Synthetically Lined Ponds
The total capital cost for construction of the naturally-lined storage pond is the
Capital Cost = Mobilization + Excavation + Compaction + Conveyance
The total capital cost for construction of the synthetically lined pond is the
Capital Cost = Mobilization + Excavation + Compaction + Conveyance + Clay Liner + Synthetic Liner
Total Annual Costs
Based on best professional judgement, annual operating and maintenance costs for
both naturally lined and synthetically lined storage ponds are estimated at 5 percent of the total
capital costs.
Annual Cost = 5% x Capital Cost
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5.5.4 ;:1.
Results
The cost model results for constructing a naturally lined storage pond, a
synthetically lined storage pond, and additional ponds for extra capacity (Option 7) are presented
in-Appendix A, Table A-7, Table A-8, and Tables A-9a and 9b,, respectively.
5.6
Nutrient Management
The cost model assumes that as part of the regulation, CAFOs will be required to
conduct certain practices to appropriately manage their nutrients. - These practices include: the
development of a nutrient management plan, soil sampling, manure, sampling, recordkeeping and
reporting costs, purchase of nitrogen fertilizer, lagoon depth marker, establishment of setback
-',' rXlV '' ' •. ; : '
areas, and calibration of a manure spreader. Each of these are described in this section. The sum
of the nutrient management costs are presented for beef feedlots, dairies, heifer and veal
i i- . L. - " - .
operations in Appendix A, Tables A-lOa and lOb. Tables A-lOc through A-lOg present costs for
- -,•••>•" J.
buffers at swine and poultry operations.
5.6.1
Nutrient Management Plan Development and Associated Costs
The cost model assumes that all but Category 3 animal feeding operations covered
by this regulation will need to develop and implement a nutrient management plan for then-
operation. To this end, there is an initial cost for the owner/operator of the farm to be trained in
nutrient management planning. Further, for all but Category 3 farms, it is assumed that the
owner/operator develops or updates then: nutrient management plan every 5 years.
On-Farm Nutrient Management Plan (NMP) Development
The cost to develop an on-farm NMP is calculated by multiplying the farm size
(number of tillable acres) by a NMP rate in dollars per acre. NMP rates vary depending on the
level of services (e.g., soil sampling, manure sampling, and analysis). EPA selected a NMP rate of
$5 per tillable acre, assuming that costs for soil and manure testing were estimated separately
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from NMP development and the higher costs for NMP development are usually attributed to
testing costs. While the final regulation requires that NMPs be rewritten at a minimum of every 5
years; therefore, the cost models for all operations include costs to revise the NMP every 5 years.
Costs for an annual review of the NMP are included under the recordkeeping requirements for all
facilities.
EPA also assumes that there will be a one-time fixed cost for documenting the
manure generation, collection, storage, and treatment systems at animal operations that require
nutrient management planning. EPA assumes that this documentation will be prepared by a
nutrient management specialist as the first step in the nutrient management planning development
process. Labor hours for both the farmer and the nutrient management specialist are required.
EPA assumes this documentation will require 8 hours of time by the farmer at $10' per hour and
16 hours of time by the nutrient management specialist at $55 per hour. This cost is:
One-time Fixed Cost
(8 hours x $10/hr) + (16 hours x $55/hr)
$960.
5.6.2
Soil Sampling
As part of nutrient management planning requirements, the cost model includes
costs for soil sampling and analysis to determine the nutrient balance of the soil prior to manure
application. Costs associated with soil sampling include a fixed cost for equipment purchase and
soil sampling costs every 3 years.
Soil Sampler
The one time capital cost for equipment was estimated to be $25 for a soil auger
(ASC Scientific, 1999). Category 3 facilities do not incur this cost since they have no land.
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Soil Sampling
The cost model assumes that on-farm soil sampling will occur at least once every 3
years. EPA selected a soil sampling rate of one composite sample per 20 tillable acres, based
upon a review of federal and state soil sampling recommendations. A composite soil sample was
estimated to take 1 hour because of the distance between samples, and labor costs for soil
sampling were estimated to be $ 10/hr. Costs for soil analysis for major nutrients and important
soil characteristics were estimated at $10 per sample based on a review of costs by state NRGS
labs. Category 3 facilities do not incur this cost since they have no land.
5.6.3
Manure Sampling
As part of nutrient management planning requirements, the cost model includes
costs for manure sampling and analysis to determine the nutrient balance of the manure prior to
application to cropland. Costs associated with manure sampling apply to all facilities and include
a fixed cost for equipment purchase and semiannual manure sampling costs.
Manure Sampler :
The one-time cost for equipment to sample liquid manure waste is estimated at $30
for a manure sampler. The manure sampler consists of a hollow conduit long enough to extend to
the bottom of the lagoon, pit, or other storage structure. In the case of solid manure, a shovel or
similar device is sufficient to obtain a representative sample and therefore no cost is assumed.
Manure Sampling
Manure sampling costs are based on sampling twice per year. The cost of manure
sampling includes the labor required and the manure nutrient analysis. For all poultry and swine
facilities, 1 hour is required to sample the main storage area. For dry poultry, an additional 0.25
hour per house is required to collect a composite sample from each house. Beef feedlots and
5-69
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dairies are assumed to have two samples of .the liquid waste and two samples of solid waste
collected per year, for a total of four samples per year.
Labor rates are estimated"at$10/hr. Manure analysis was estimated at $40 per
sample based on a review of costs by state soir conservation service labs.
5.6.4
Recordkeeping and Reporting
As part of implementing a nutrient management plan, the cost model assigns
annual costs to each facility for recordkeeping and reporting time. Recordkeeping costs
($880/year) for all facilities include the cost of recording animal inventories, manure generation,
field application of manure and other nutrients (amount, rate, method, incorporation, dates),
manure and soil analysis compilation, crop yield goals and harvested yields, crop rotations, tillage
practices, rainfall and irrigation, lime applications, findings from visual inspections of feedlot areas
and fields, lagoon emptying, and other activities on a monthly basis.
EPA estimated that large facilities incur an additional cost of $1407 year to
maintain records of manure that is transferred to a third party. The average number of transfers
per large CAPO is 16,900, based on.excess manure estimates in Simons (2002). Using the 100-
ton transfer estimate from Simons (2002), the average annual number of transfers per CAFO of
169 (16,900 •*• 100). It should not require more than five minutes per transfer to record the four
data items: the name of the recipient, the data of the transfer, the quantity of manure, and its
nutrient content. Therefore, the annual burden estimate will be approximately 14 hours (169
transfers x 5 minutes/transfer -=- 60 minutes/hour). The additional $8.50 cost per 20-ton load to
weight a truck (Simons, 2002) is not a required cost of the rule and, therefore, is excluded from
the offsite transfer cost estimate.
Records may include manure spreader calibration worksheets, manure application
worksheets, maintenance logs, soil and manure test results, and documentation of corrective
actions taken in response to findings from visual inspections. EPA assumed 8 hours were needed
to prepare an annual report on animal inventories, manure generation, and overall manure
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application. Monthly write-ups and field observations are assumed to require 3 hours each (72
hours annually). Thus, a total of 80 hours annually was estimated for recordkeeping at $10/hour.
Other costs associated with recordkeeping, including obtaining signed certifications of proper
manure application from off-site manure recipients, were estimated at 10 percent of labor costs.
5.6.5
Commercial Nitrogen Fertilizer
The nitrogen-to-phosphoras ratio in manure is typically much lower
(approximately 2:1) than harvested crop nutrient removal ratios (approximately 6:1). Therefore,
facilities that must land apply their manure on a phosphorus basis rather than a nitrogen basis
incur additional costs because a commercial source of nitrogen must be applied to their fields
(termed sidedressing) to compensate for the nitrogen not supplied through manure application.
The cost model assumes a cost of 12.30 per pound of additional nitrogen is required, based upon
the cost data shown in Table 5.6.5-1. No,veal operations are assumed to need commercial
fertilizer. Appendix A, Table A-l 1 presents the cost model results for purchasing commercial
nitrogen fertilizer for beef feedlots, dairies, heifer, and veal operations.
5.6.6
Table 5.6.5-1
Retail Cost of Nitrogen Fertilizer
Fertilizer
Anhydrous Ammonia
Urea
Ammonium Nitrate
U.S. Average
RetaH Cost Per Pound of Nitrogen ; :j
140
120
110
12.30
Source: The Fertilizer Institute, 1999.
Lagoon Depth Marker
EPA believes that all facilities with liquid waste impoundments should have a •
gauge to measure the remaining storage capacity. A lagoon depth marker can be manufactured by
purchasing PVC pipe, fittings, and cement to construct a length of incrementally marked pipe long
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enough to reach the bottom of the lagoon and extend above the freeboard. EPA estimated lhat
building and installing a lagoon depth marker would cost $30.
5.6.7
Establishment of Setback Areas
The final rule requires either (1) a 100-foot manure application setback from
surface waters, sinkholes, open tile dram inlets, or (2) a 30-foot vegetated buffer from surface
waters, sinkholes, open tile drain inlets, or (3) one or more NRCS field practices providing an
equal or better level of protection (a certified CNMP is deemed to meet this requirement).
However, EPA believes that in addition to manure application setbacks from.
surface waters, operations should also establish buffer strips or their equivalent to control erosion
and treat field runoff. Thus, EPA estimated the costs of 100-foot .buffer strips for fields used for
manure application that are adjacent to streams, discussed below.
The costs of the buffer should be thought of as an,allowance for the AFO to
implement site specific field control practices such as conservation management. In other words,
controls other than buffer strips may be more effective in certain situations (Sims J., A. Leytem, F.
Coale, 2000), and this cost basis is considered an allowance that can be used to implement other
runoff control practices.
Initial Fixed Costs
EPA calculated the ratio of stream length to land area based on national estimates
of land area (3 million square miles of land in the contiguous United States (ESRI,1998) and
stream miles (3.5 million miles of streams (USEPA, 2000). This ratio was converted to miles per
acre (0.00144 mile of stream per acre of land). EPA then calculated the amount of land needed
for buffer construction by multiplying the average acres of cropland for each model farm by the
ratio of stream miles per acre of land, which determined the length of stream on each farm. EPA
further assumed that the farm is square and the stream runs down the middle of the farm, and the
width of the buffer (on both sides of the stream) is 100 feet. The cost of 100-foot buffers was
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based on information collected from a total of 914 filter strip projects in 28 states with an average
cost of $106.62/ac (1999 dollars; USEPA, 1993). The net loss of tillable land to establish a buffer
was estimated at 3.5 percent of the cropland (0.00144 mile of stream per acre x 5,280 feet per
mile x 200 ft2 of buffer per foot of stream length -*- 43,560 fWac). Thus, the cost for stream
buffers was estimated at approximately $3.72/ac of total cropland.
Annual Costs
EPA assumed that the land taken out of production for installation of buffer strips
was previously farmed. The rental value for land taken out of production was added to standard
O&M costs. The rental value for cropland used as a stream buffer was estimated at $64.00/ac/yr
based on analysis by North Carolina State University (NCSU, 1998).
5.6.8
Manure Spreader Calibration
EPA assumed that regular calibration of the manure spreader is part of
implementing the nutrient management plan. To meet this need, EPA assumed that Category 1
and 2 facilities will purchase two calibration scales to weight the manure spreader before and after
land application.
In cases where states require calibration of manure spreaders at broiler and turkey
facilities, EPA assumed that calibration scales (or an equivalent calibration technology or method)
are available to the facility, and therefore no costs were assumed. Solid manure spreaders can be
calibrated in a number of ways, some of which are based on volume instead of weight. Liquid-
based systems can also be calibrated in terms of volume. Section 8 of the Technical Development
Document describers methods for calibration of manure spreaders in greater detail.
Weighing the spreader before and after application is the ideal methodology for
wet or dry manure calibration because it is relatively quick and produces accurate results. This
approach is unsuitable for manure application devices such as umbilical applicators. Instead, the
volume of manure injected must be first be determined. The procedure includes collecting
5-73
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pumped material into a bucket to determine the flow rate, which decreases initial calibration costs.
Some operations that handle their manure in a drier form may be able to use a less expensive
calibration method. For example, spreading manure on a tarp and-weighing it on a less expensive
hanging balance would reduce initial calibration costs. '
Fixed One-Time Costs
EPA assumed the one-time cost for equipment is $500 for a scale to weigh the
manure spreader (one under each wheel at $250 each). '"''"• ••''•'
Annual Costs ' ;
EPA estimated the cost for manure spreader calibration to be $ 100 based on 4
hours of labor, at $10 per hour, for both wet and dry applicators and 2 hours of tractor time at
$30 per hour. EPA assumed that the time required for calibration included gathering required
equipment, loading manure, weighing the spreader before and after land application, and applying
manure to a known area of cropland. Category 3 facilities do not incur this cost since they have
no land.
5.7
Screen Solid-Liquid Separation for Swine Operations
Solid-liquid separation systems are used by many livestock operations as a way to
manage waste. Solid-liquid separation is the partial removal of organic and inorganic solids from
a mixture of animal wastes and process-generated wastewater (known as liquid manure).
Separating the solids from the liquid manure makes the liquids easier to pump and handle. The
cost model assigns costs to swine operations for screen separation.
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5.7.1
Technology Description and Design
Typically, screens are used to separate the solids from the liquids. As the liquids
pass through the screen, the solids accumulate", and are eventually collected. After collection, the
solids may be handled more economically for hauling, composting, refeeding or generating biogas
(methane). EPA assumes that the separator efficiency is 30 percent and that the solids content of
the separate.d.manure is 23 percent.
The approach taken in the cost model is to separate the solid from the liquid
portion of the manure to concentrate the nutrients thus reducing the costs associated with hauling
the excess nutrients. Both Category 2 and 3 swine facilities are given costs for solid-liquid
separation with screens.
5.7.2
Costs
Costs for solid/liquid separation are estimated as a one-time, fixed cost and an
annual cost, based on the following calculations. Costs include a tank with sufficient capacity to
store solids for six months, a mechanical solids separator, piping, and labor for installation.
Capital Cost
The following equation determines the initial cost to install a separator on a swine
operation:
Sepinitial = (Solids x Safety x Tankcost) + Separator + Pipelen x Pipecost + Seplabor x Labor
where:
Sepinitial
Solids
Safety
Tankcost
Initial cost ($) to install a separator system
Volume of solids separated from the manure every 6
months, gal
Safety factor providing additional storage for the
separator (115%)
Cost of installing a steel storage tank ($0.18/gallon)
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Separator
Pipelen
Pipecost
Seplabor
Labor
Cost of a separation device was estimated at
$13,000 for medium-sized operations and $28,000
for large operations, (USDA.NRCS, 2002a)
Pipe length needed to connect the lagoon to the
separator (250 feet)
Cost of pipe ($2.13/foot)
Time required to install the pipe and separator (4
hours)
Labor rate per hour ($10).
Annual Costs
The annual cost of operation and maintenance of solid-liquid separation systems
was estimated to be 2 percent of the total cost of installing 'the system.
5.8
Land Application
The purchase of land application equipment is a primary component of the
compliance costs for beef feedlots and dairies estimated by the cost model. The cost model
estimates costs for the purchase of irrigation equipment to apply liquid from ponds and lagoons to
the fields. The model assumes that all facilities already have equipment to apply solid manure and,
therefore, includes no cost for this. As described in Section 4.10, the cost model calculates the
total crop acreage used for application of liquid waste based on the nutrient assimilative capacity
of the crops and the total waste generated, and uses this total acreage to cost irrigation
equipment. The cost model includes no costs for application equipment for swine and poultry
operations.
The cost model uses two forms of irrigation, center pivot and traveling gun.
Center pivot irrigation is ideal for applying liquid waste to a large number of acres but is not as
cost-effective for smaller acreage. Therefore, the cost model estimates costs for center pivot
irrigation for facilities applying liquid manure to crop acreage greater than or equal to 30 acres
and for traveling gun irrigation for facilities applying liquid manure to less than 30 acres.
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5.8.1
Center Pivot Irrigation
Center pivots are a'-method of precisely inigating virtually any type of crop over
large areas of land. This technology is more expensive than other methods of irrigation, and
• i± • •** • ! H '. - v.' •• • '. \ . ,.•.', -
therefore, costs included in the cost model for center pivot irrigation are conservative. A center
pivot can effectively distribute liquid animal waste and supply nutrients to cropland at agronomic
rates because they have a high level of control. The center pivot design is flexible and can be
adapted to a wide range of site and wastewater characteristics. Center pivots are also
advantageous because they can distribute the wastewater quickly, uniformly, and with minimal
soil compaction. In a center pivot, an electrically driven lateral assembly extends from a center
point where the water is delivered, and the lateral circles around this point, spraying water. A
center pivot irrigation system is costed for all operations applying liquid manure to more than 30
acres of cropland under all regulatory options.
Technology Description
A center pivot generally uses 100*. to more than 150 pounds of pressure per square
inch (psi) to operate, which requires a 30- to 75-horsepower motor. The center pivot system is
constructed mainly of aluminum or galvanized steel and consists of the following main
components:
Pivot: The central point of the system around which the lateral assembly
rotates. The pivot is positioned on a concrete anchor and contains
various controls for operating the system, including timing and flow
rate. Wastewater from a lagoon, pond, or other storage structure is
pumped to the pivot as the initial step in applying the waste to the
land.
Lateral: A pipe and sprinklers that distribute the wastewater across the site
as it moves around the pivot, typically 6 to 10 feet above the
ground. The lateral extends out from the pivot and may consist of
one or more spans depending on the site characteristics. A typical
span may be from 80 to 250 feet long, whereas the entire lateral
may be as long as 2,600 feet.
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Tower: A structure located at the end point of each span that provides
support for the pipe. Each tower is on wheels and is propelled by
either an electrically driven motor, a hydraulic drive wheel, or liquid
pressure, which makes it possible for the entire; lateral to move
slowly around the pivot.
Figure 5.8.1-1 shows a schematic of a center pivot irrigation system.
Storage
Rjrrp—•>
Figure 5.8.1-1. Schematic of Center Pivot Irrigation System
All regulatory options are based on the installation of irrigation equipment a.t beef
feedlots, dairies, and heifer operations that land apply waste on site (i.e., Category 1 and 2
facilities). EPA developed frequency factors for center pivot irrigation based on the frequency
factors for an unlined pond or lagoon. EPA assumed that if a facility has an unlined pond or
lagoon on site, the facility would also already have some method of land application equipment to
land apply the wastewater from this lagoon. These frequency factors are presented in Section 6.0.
The cost model does not include costs for veal operations for center pivot irrigation because they
are assumed to have sufficient storage capacity and therefore the necessary irrigation equipment.
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Design
The center pivot is designed specifically for each operation, based on wastewater
volume and characteristics, as well as site characteristics such as soil type, parcel geometry, and
slope. The soil type (i.e., its permeability and infiltration rate) affects the selection of the water
spraying pattern. The soil composition (e.g., porous, tightly packed) affects tire size selection as
to whether it allows good traction and flotation. Overall site geometry dictates the location and
layout of the pivots, the length of the laterals, and the length and number of spans and towers.
Center pivots can be designed for sites with slopes of up to approximately 15 percent, although
this depends on the type of crop cover and methods used to alleviate runoff. The costs assume a
regular-shaped parcel (square), a water requirement of 7 gallons per minute per acre, and 1,000
operating hours per year.
5.8.2
Traveling Gun Irrigation
Based on industry expert opinion and literature, farms can irrigate relatively small
areas using a traveling gun (USDA NRCS, 1996). Traveling guns are also useful in oddly shaped
fields. These systems can be installed rapidly and are easily transported. However, the operation
of traveling gun systems is more labor intensive than the operation of center pivot systems.
Another disadvantage of traveling gun systems is low application efficiency. Water is sprayed
high into the air, causing wind and evaporation losses up to 30 percent (Clemson Extension,
2002). The traveling gun system requires higher capital, annual, labor, and energy costs per
irrigated acre than the center pivot system (Agriculture and Agri-Food Canada, 2002). Despite
the disadvantages, traveling gun irrigation systems remain the best alternative for small acreages.
A traveling gun system is costed for all operations with less than 30 acres of cropland under all
regulatory options.
Technology Description
Traveling gun systems consist of a large sprinkler, a wheeled cart, a hose reel, and
an irrigation hose. The sprinkler is also referred to as the "gun" or "big gun." The sprinkler is
5-79
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moved during irrigation, hence the name "traveling gun." Traveling gun sprinklers discharge 50
to 1,000 gallons per minute with operating pressures from 60 to 120 psi (USDA NRCS,1996). A
traveling gun sprinkler is mounted on a wheeled cart to allow for mobility. An irrigation hose is
connected to the sprinkler on the wheeled cart and contained in a hose reel. There are two types
of traveling gun operations depending on the type or irrigation hose used:
Hard-Hose - This type of traveling gun operation utilizes a hard, high-pressure,
polyethylene hose. The hose is pulled out some distance from the hose reel. As
the sprinkler operates, the hose reel begins to reel in the cart and sprinkler.
Soft-Hose - This system may also be called a Cable-Tow system. A soft, flexible
hose similar to a fire hose is used. The entire hose must be unwound from the
hose reel before use. The wheeled cart is placed in the field and anchored by a
cable. A winch on the cart pulls reels the cable, pulling the cart closer to the
anchor. The lu>se drags behind the cart and must be manually reeled after use.
The sprinkler travels a straight path, wetting a 200-400 foot wide strip of land
(USDA NRCS, 1996). When one path is complete, the unit must be moved to an adjacent path to
make another pass at the field. This process is repeated until the entire field is irrigated.
EPA developed frequency factors for traveling gun irrigation based on the
frequency factors for an unlined pond or lagoon. These frequency factors are presented in
Section 6.0. EPA assumed that if a facility has an unlined pond or lagoon on site, the facility
would also akeady have some method of land application equipment to land apply the wastewater
from this lagoon. The cost model does not include costs for veal operations because they are
assumed to have sufficient storage capacity.
Design
The traveling gun is designed specifically for each operation, based on wastewater
volume and characteristics, as well as site characteristics such as soil type, parcel geometry, and
slope. The soil type and composition affects the selection of the water spraying volume.
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5.8.3
Beef and Dairy Irrigation Costs
The only variable the cost model uses to determine costs for a center pivot and
traveling gun irrigation systems are total acres irrigated.
Center Pivot
EPA derived annual arid capital costs for center pivots from cost curves created
from data available at a vendor web site (Zimmatic, Inc., 1999). Number of irrigated acres (61,
122, and 488) are plotted on the x-axis and costs (capital and annual) are plotted on the y-axis.
Capital costs include the pivot, lateral, towers, pumps, piping, generator and power units, and
erection. Annual costs include power consumption and routine maintenance of mechanical parts.
Table 5.8.3-1 presents the costs for each of these points.
Table 5.8.3-1
Costs for Data Points from Center Pivot Irrigation Cost Curves
Number of Irrigated Acres
61
122
488
Gapitel Costs
$58,741
$64,130
$122,414
Annual Costs
$3,453
$5,616
$11,559
Source: http://www.Zimmatic.com.
Traveling Gun
Traveling gun costs are based on information provided by Kifco, Inc., an
agricultural irrigation company. The cost model assumes that 250-gpm applicators would provide
adequate coverage for cropland comprising less than 30 acres. Table 5.8.3-2 presents the capital
costs for a 250-gpm applicator. Annual costs are estimated at five percent of the capital costs.
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Table 5.8.3-2
Costs for 250-gpm Liquid Applicators
1 Model
37M/1220
40A/1320
Flow Rate (gpm)
225-415'
250-480
Capital Cost
$28;990 r
$31,400
Source: (Kifco, 2002) """
•..:••::- ••:,'..' i-'U >•.;?.>. ;.u-r
Total Capital Costs
:v'i I'i,
' A polynomial curve with a regression coefficient of 1 'is drawn through the capital
cost points. The cost model uses the resulting curve to estimate costs for the various acreages.
The equation is:
where:
y
x
y = 0.166x2 + 57.958x + 54,588
Capital cost
Irrigated acreage.
Total Annual Costs
A logarithmic curve with a regression coefficient of 0.9947 is;drawn through the
annual cost points. The cost model uses the resulting curve to estimate costs for various
acreages. The equation is:
y = 3954 In (x)-13,033
where:
y
x
Annual cost
Irrigated acreage.
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Results
Appendix A, Tables A-12a and A-12b present the cost model results for
implementing center pivot or traveling gun irrigation systems at beef feedlots, dairies, and heifer
operations.
5.9
Transportation
Animal feeding operations use different methods of transportation to remove
excess manure waste and wastewater from the feedlot operation. The costs associated with
transporting excess waste off site are calculated using two methods: contract hauling waste or
purchasing transportation equipment. EPA evaluated both methods of transportation for all
regulatory options. The least expensive method for each model farm and regulatory option is
chosen as the basis of the costs. Hauling at swine and poultry operations is assumed to be
accomplished via contract hauling.
5.9.1
Technology Description
Many animal feeding operations use manure waste and wastewater on site as
fertilizer or irrigation water on cropland; however, nutrient management plans (discussed in
Section 5.6) require that facilities apply only the amount of nutrients agronomically required by
the crop. When a facility generates more nutrients in its manure waste and wastewater than can
be used for on-site application, they must transport the remaining manure waste and wastewater
off site.
Beef feedlots, dairies, swine operations, and poultry operations are divided into
three categories, as discussed in Section 1.3. Category 1 operations have sufficient cropland to
agronomically apply all of their generated waste on site. Category 2 operations do not have
sufficient cropland and may only agronomically apply a portion of their generated waste.
Category 3 operations have no cropland and must transport all of their waste off site. The number
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of operations in each category depends on the nutrient application requirements, because more
land is required for nitrogen-based application than for phosphorus-based application.
The amount of excess waste that requires transport depends on the nutrient basis
used for land application, as well as the practices and technologies employed at the facility (e.g.,
feeding strategies). Option 1 requires that animal waste be applied on a nitrogen basis to
cropland, and Options 2 through 7 require application on a phosphorus basis as dictated by site-
specific conditions. In general, the amount of waste transported off site increases under a
phosphorus-based application option. Section 4.9 discusses the methodology used to determine
the amount of excess waste at beef feedlots, dairies, swine operations, and poultry operations.
Manure is transported as either a solid or liquid material. The cost model assumes
that solid waste is transported before liquid waste because it is less expensive: to haul solid waste.
This assumption means that operations apply liquid manure (i.e., lagoon and pond effluents;) to
cropland on site before solid waste.
In addition, some operations are located in states that already require them to
apply manure to cropland on an agronomic nitrogen basis; therefore, these operations will not
incur additional transportation costs under the N-based scenario. The percentage of facilities that
are expected to incur transportation costs was based on EPA's Interim Final Report: State
Compendium: Programs and Regulatory Activities Related to Animal Feeding Operations -
Interim Final Report (EPA, 1999) and is discussed in detail in Section 6.0 of this report.
Contract Hauling
One method evaluated for transporting manure waste off site is contract hauling,
whereby the operation hires an outside firm to transport the excess waste. This method is
advantageous to facilities that do not have the necessary capacity to store excess waste on site or
the cropland acreage to agronomically apply the material. In addition, this method is useful for
operations that do not generate enough excess waste to warrant purchasing their own waste
transportation trucks. Contract haulers can transport waste from multiple operations.
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Equipment Purchase
Another method evaluated for transporting manure waste off site is to purchase
transportation equipment. In this method, the operation owner purchases the necessary trucks to
haul the waste to an off-site location. Depending on the type of waste transported, a solid waste
truck, a liquid tanker truck, or both types of trucks are required. In addition, the owner is
responsible for determining a suitable location for the waste, as well as all costs associated with
loading and unloading the trucks, driving the trucks to the off-site location, and maintaining the
trucks.
5.9.2
Design and Costs of Contract Hauling
In determining costs for the contract-hauling option, the cost model considered
three major factors:
1) Amount of waste transported;
2) Type of waste transported (semisolid or liquid); and
3) Location of the operation.
Additional factors that relate to these three major factors include:
• Hauling distance;
• Weight of the waste;
• Rate charged to haul waste ($/ton-mile); and
• Percentage of operations in each region and category that incur transport
costs.
Using these factors, the cost model uses the following three steps to determine
costs for a model farm:
Step 1) Determine constants, based on region, animal type, and waste type;
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Step 2) Determine the weight of the transported waste, accounting for
water losses during storage or composting; and
Step 3) Determine the annual waste transportation costs.
Each of these steps is explained in detail below.
Step 1) Determine constants, based on region, animal type, and waste type
Constants used in this evaluation include the hauling distance, the moisture content
of stockpiled manure, the moisture content of composted manure, and the hauling rate ($/ton-
mile).
Hauling Distance
The one-way hauling distance for a Category 2 or 3 operation depends on the
region in which it is located. The one-way hauling distance considers the size of the county,
whether the county has a potential for excess manure nutrients, and the proximity of other
counties that have a nutrient excess. The cost model assumes that Category 3 operations have
always transported all of their waste; however, the cost model also assumes that the distance
required for transport would increase under the P-based scenario. Therefore, the distance
assigned to Category 3, P-based facilities is an incremental distance, representing the difference in
distance a facility would have to transport under the P-based option. (For more details, see
Revised Transportation Distances for Category 2 and 3 Type Operations, Terra Tech, 2000.)
The P-based hauling distance is reduced where feeding strategies are used to
reduce swine manure-P by 40 percent. EPA assumes that if total manure P is reduced by 40
percent, facilities will not have to haul their excess manure as great a distance. The cost model
counted all major animal types in determining counties with nutrient excess. (Analysis based on
Kellogg, R. et al., 2000.) Table 5.9.2-1 presents the Category 2 and Category 3 hauling distances
by region.
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Table 5.9.2-1
Hauling Distances for Transportation
^ ';• •••••^•Region
Central
Mid-Atlantic
Midwest
Pacific
South
. One-Way fiauling Distance (miles) for
Category 2
N-Basis
11.0
5.5 .
6.5
12.5
6.0
P-Basis
16.5
30.5
10.0
21.5 .
14.5
P-Basis*
NA
18
NA
NA
NA
One-Way Hauling Distance (miles) for
Category 3
N-Basis
0
0
0
0
•: 0 "
P-Basis
5.5
25.0
3.5
9.0
8 5
P-Basis*
NA
18
NA
NA
NA
source: for detailed information on the calculation of one-way hauling distances, see Revised Transportation Distances for
Category 2and3 Type Operations. TetraTech, 2000. •>"•'•. , .
*P-Basis when feeding strategies are used to reduce total P by 40 percent.
Moisture Content of Waste -
Based on available information, the cost model assumes that the moisture content
of stockpiled manure is 35.4 percent and the moisture content of composted manure is 30.8
percent (Sweeten, J.M. and S.H. Amosson, 1995).
Hauling Rate
The $/ton-mile rates for liquid and solids wastes for Category 2 and 3 beef feedlots
and dairies are estimated based on information obtained from various contract haulers and
presented in Table 5.9.2-2. The hauling rates used for swine and poultry operations are presented
in Table 5.9.2-3.
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Table 5.9.2-2
Rates for Contract Hauling for Category 2 and 3 Beef Feedlots and Dairies
Type of Waste
Solid ($/ton-mile)
Liouid ($/ton-niile)
Category 2 Rates •
N-Based
Application
0.24
0.53
P-Based :
Application
0.15
0.10
.;.... Jtf-B.a]se3;-;'.;:';
Application
0
0
P=-Basfed
Application .
0.08
0.26
Source: For additional detail on the calculation of contract hauling rates, see Methodology, to Calculate Contract
Hauling Rates for Beef and Dairy Cost Model, ERG 2000.
Table 5.9.2-3
i
Hauling Rates for Category 2 and 3 Swine and Poultry Operations
Type of Waste
Liquid - First Mile ($/gallon-mile)
Liquid - Beyond First Mile ($/gallon-mile)
Solid - Less than 90 Miles ($/ton-mile)
Solid - 90 to 1230 Miles ($/ton-mile)
Solid - Beyond 1230 Miles ($/ton-mile)
• ' '. ; v. ,.-'"; • ' "Rate, •'.; •'•;'" V>V .:_ ' '
0.008
0.0013
0.10
0.23
0.18
Source: Tetra Tech, 2002.
Step 2) Determine the weight of the transported waste
The amount of waste to be transported is estimated as the sum of separated solids,
lagoon's pond effluent, lagoon's pond accumulated solids, and process and rainwater not applied
to land.
Step 3) Determine the annual cost of transporting the waste
The annual cost of hiring a contractor to haul the waste is based on the amount of
waste (in either semisolid or liquid form), the distance traveled, and the haul rate. The following
equation incorporates both the solid and liquid annual hauling costs:
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... Annual Cost = (Weight of Solids x Solid Hauling Rate x Hauling Distance Roimd-trip) +
(Weight of Liquids x Liquid Hauling Rate x Hauling Distance Roumi.trip)
There are no capital costs associated with contract hauling. All hauling costs for
swine and poultry operations are calculated using this basic approach for cdntract hauling.
5.9.3
Design and Cost of Purchase Equipment Transportation Option
In determining costs for the purchase truck transportation option, the cost model
considered three major factors:
1) Amount of transported waste;
2) Type of waste transported (semisolid or liquid); and
3) The location of the operation.
Additional factors that relate to these three major factors include:
•' Hauling distance;
• Number of hauling trips required per year;
• The waste volume;
• Average speed of the truck;
• Cost of fuel;
• Cost of maintenance;
• Cost of purchasing the truck;
* Cost for labor for the truck driver; and
• • Percentage of facilities in each region and category that incur transport
costs under the proposed regulatory options.
Using these factors, the cost model completes the following six steps to determine
costs for a model farm:
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Step 1) Determine constants, based on region, animal type, and waste type;
Step 2) • Determine the weight of the waste transported, accounting for
water losses during storage or composting;
Step 3) Determine the number of trucks and number of trips required to
haul all of the waste each year;
Step 4) Determine =the number of hours required to transport waste each
year;__. . _.
Step 5) Determine the purchase cost for the trucks required to transport the
"waste; and, .. - . - —.
Step 6) Determine the annual cost to transport the waste.
Each of these steps is explained in detail below.
Step 1) Determine constants, based on region, animal type, and waste type
Constants used in this evaluation include the hauling distance, the average speed of
the truck, the moisture content of stockpiled manure, the moisture content of composted manure,
the hours spent hauling per day, the loading and unloading time, the fuel rate, the maintenance
rate, the hourly hauling rate, the volume of waste the truck can haul, and the purchase price of the
truck.
Hauling Distance
The one-way hauling distance for an operation depends on the region in which it is
located and what category operation is being evaluated. For each region, the average distance the
waste must be hauled varies according to regional factors. Table 5.9.2-1 presents these distances.
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1995).
Average Speed
The average speed of the truck is estimated to be 35 miles per hour (USEPA,
Moisture Content of Waste
Based on available information, the moisture content of stockpiled manure and
composted manure is estimated to be 35.4 percent and 30.8 percent, respectively Sweeten, J.M.
and S.H. Amosson, 1995). .......
Working Schedule
The cost model estimated that one laborer requires 25 minutes to load and unload
the truck and hauls waste for 7 hours per day (USEPA, 1995).
Fuel Rate
The diesel fuel is estimated to cost $1.35 per gallon (Jewell, W.J., P.E. Wright,
N.P. Fleszar, G. Green, A. Safinski, A. Zucker, 1997).
Maintenance Rate .
The estimated maintenance rates for liquid and solid waste trucks are $0.63 per
hauling mile and $0.50 per hauling mile, respectively (Jewell, W.J., P.E. Wright, N.P. Fleszar, G.
Green, A. Safinski, A. Zucker, 1997; USEPA, 1995).
Labor Rate
The rate used in the cost model for the laborer to load, unload, and haul the waste
is $10 per hour.
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Capacity and Prices of Trucks
The size of the solid waste trucks vary, depending on the amount of waste that is
>' I. : ---".i ; i- ," • • ; ••• • -- - " ': • : f
hauled. The standard sizes and purchase prices for solid waste trucks used in the cost model are
(USEPA, 1995):
7-cubic-yard truck = $91,728
10-cubic-yard truck =$137,593
- ' " , "•'•' !' ''.•''.: 'l:>Jj t. .:'''. . • • • '! ',' !
15-cubic-yard truck = $183,457
25-cubic-yard truck = $241,054
The size of the liquid waste trucks also varies, depending on the amount of waste
that is hauled. The standard sizes and purchase prices for liquid waste trucks used in the cost
model are (USEPA, 1995):
1,600-gallon truck = $84,262
2,500-gallon track = $113,061
4,000-gallon truck = $140,792
Step 2) Determine the weight of the waste transported
The amount of waste to be transported is estimated as the sum of separated solids,
lagoon's pond effluent, lagoon's pond accumulated solids, and process and rainwater not applied
to land.
Step 3) Determine the number of trips required to haul all of the waste per year
To determine the number of trips per year required to haul all of the waste, the
cost model performs the following calculations. First, the size of the truck is determined. Then,
the maximum possible number of trips per year is calculated, given the hauling schedule arid the
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number of days the truck is available for transport per year. A test is then performed to see if the
truck size selected is large enough to transport all of the waste requiring transport within the time
frame calculated as the maximum number of trips per year. If the track is not large enough, then
the cost model assumes that multiple trucks are purchased, and recalculates the equations based
on the larger capacity.
The equation for the maximum number of trips per year is:
Maximum Trips / yr =
(Haul Schedule x Haul Days)
(Truck Loading Time + Track Unloading Time -t- Track Haul Time)
The capacity of the truck is determined through an iterative process that
substitutes the size of the track (10 cubic yards (CY), 15 CY, and 25 CY) and the number of
tracks (1 or 2) into the following equation until the number of trips per year is greater than the
maximum number of trips per year:
Number of Trips/yr =
Solid Waste (as collected)
(Number of Tracks x Capacity of Truck)
The equation for the actual number of trips per year is:
Actual Trips/ yr
Solid Waste (as collected)
(Number of Trucks x Capacity of Truck)
(Note: The number of tracks is rounded up to the nearest whole number.)
Step 4) Determine the number of hours required to transport waste each year
The number of hours required to transport all of the waste each year is based on
the hauling time, the loading and unloading time, and the actual number of hauling trips per year,
as. shown below:
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Transport Hours = (Truck Loading Time + Truck Unloading Time + Truck Haul Time) x Number of Trips
Step 5) Determine the purchase cost of the trucks required to transport the waste
The purchase cost of the truck(s) depends on the number of trucks needed arid the
cost for that size of truck, as shown below:
Purchase Cost = Number of Trucks x Cost of Truck
Step 6) Determine the annual cost to transport the waste
The annual operating and maintenance cost for owning and operating the trucks is
based on the fuel spent, the maintenance rate per mile driven, and the labor costs. This is
calculated for both the liquid waste transport and the solid waste transport. The equation for the
annual cost is:
Annual Cost = (Maintenance Rate x Hauling Distance Round.trip x Number of Trips + Transport
Hours x Labor Rate + Hauling Distance Round.,rip x Number of Trips / Fuel Rate) x Number of Trucks
5.9.4
Transportation Cost Test
When evaluating costs to transport waste off site, the cost model considered
purchasing a truck to transport waste and hiring a contractor to haul waste as the two scenarios
for the model beef feedlots, dairies, and veal operations. Because the weight and volume of the
manure directly impact the transportation costs, each scenario was also considered with
composting the waste prior to hauling and without composting. This section discusses the test
used to determine which scenario is least costly for each model farm.
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Purpose of the Cost Test
When animal feeding operations are unable to apply all of their waste on site at the
appropriate agronomic rate, the waste is transported off site to a location where the waste is
applied at the agronomic rate. EPA considered two methods of off-site transport: 1) hiring a
contractor to haul the waste; or 2) purchasing a truck to move the waste without third-party
assistance. In addition, animal feeding operations can choose to compost their waste before
hauling to reduce the weight and volume of the waste and to improve the quality of the end
product (see Section 5.12). EPA assumes that operations will choose the transportation and
composting pair that is least expensive., To determine which method a beef feedlot, dairy,-or veal
operation will choose, the cost model conducts a test that compares the costs annualized over 10
years: , ; - - ~ .
For each model farm that transports waste off site under Options 1 through 4,6,
and 7, the cost model assumes that the-.operation uses one of four transportation scenarios:
1) Composting with contract haul;
2) Composting with purchase truck;
3) No composting with contract haul; and
4) No composting with purchase truck.
For Option 5A, only transportation scenarios with composting are considered.
Cost Test Methodology
The transportation scenario that is costed for each operation is the least costly
when annualized over 10 years. To determine this, each transportation scenario is costed
separately. The cost for each transportation scenario is then added to the weighted farm costs to
create four possible model farm costs, with capital costs and annual costs. Each of these is
annualized, using the following equation:
A(n) = P x I x (l +1)° / [(1 + I)n - 1] + A
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where:
A(n)
P
I
n
A
Annualized cost over n years
Capital cost
Interest rate ,, ., ..
Number of years
Annual cost.
The least expensive annualized cost of the four transportation scenarios is selected as the
preferred scenario.
5.9.5
Results
Appendix A, Table A-13a presents the cost model results for transporting manure
waste using contract hauling or purchasing transport equipment when applying on a nitrogen basis
for beef feedlots, dairies, and heifer operations. Appendix A, Table A-13b presents the cost
model results for transporting manure waste using contract hauling or purchasing transport
equipment when applying on a phosphorus basis for beef feedlots, dairies, and heifer operations.
Appendix B presents the selected transportation method for each of these model farms.
5.10
Ground-Water Assessment and Monitoring
Storing or treating animal waste at or below the ground surface has the potential
to contaminate ground water. Ground-water wells may be used at animal feeding operations to
monitor ground-water contamination. For Option 3A/3B, a ground-water assessment is used to
determine whether a direct hydrologic connection to surface water exists. Ground-water well
installation and associated monitoring is then costed for all model farms where there is a direct
hydrologic connection between ground water and surface water.
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5.10.1
Technology Description
Manure and waste that infiltrates into the soil, and is not taken up by crops, may
i
contaminate underlying aquifers with nutrients, bacteria, viruses, hormones, and salts. Irrigation
of manure may also contaminate aquifers with salt and high levels of total dissolved solids. In
turn, such manure and waste may contaminate surface water which has a direct hydrologic
connection to the ground water. Ground-water wells can be installed to monitor for these
pollutants.
Geologic conditions, as well as the elevation and shape of the water table, vary
based on region. A hydrogeologic site investigation may occur prior to well installation to
determine site conditions and to determine the number and location of samples as well as the
sampling .depth.
5.10.2
Design and Costs
. The design for the ground-water wells does not vary according to animal type or
size of facility. It is assumed that each facility determined to have a direct hydrologic connection
will install four 50-foot ground-water monitoring wells, one up-gradient and three down-gradient
from the manure storage facility, as shown in Figure 5.10.2-1.
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Manure
Top of casing
Groundwater -"
monitoring
well
(up-gradient)
-•-..^___
_s_
5
_i
storage facility
(manure stockpile)
_ Ground / _
.surface ^*" " -^
Groundwater
monitoring
well
(down-gradient)
Water table
C-
JZ_
t / /
5
Q'
Figure 5.10.2-1. Schematic of Ground-Water Monitoring Wells
Assessment of Crop Field and Ground-Water Links to Surface Water
Because the assessment of ground-water links to surface water requires
professional expertise, EPA estimates pay rates of $75 per hour for field work and report writing,
and $65 per hour for research related to this task. Assessment activities include a limited review
of local geohydrology, topography, proximity to surface waters, and current animal waste
management practices. EPA estimates that the assessment activities would require 2 days of
work at the operation, 2 days of office work, and 2 days to compile the data into a final report. In
addition, EPA assumes that a farmhand spends 8 hours assisting in the assessment. EPA
estimated that miscellaneous expenses, including travel time, photocopying, purchasing, maps,
and report generation are 15 percent of total costs. This one-time assessment does not vary with
the size or type of operation; therefore, the cost is the same for each model farm. The one-time
labor cost does not vary by model farm and is calculated as follows:
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geographic location, method of manure collection, and the type of waste management system.
Table 5.13.2-1 summarizes the inputs used for both the covered lagoon and complete mix
digesters. User-selected input values are npted with the letter "S" in brackets, [S]. Default input
values that are selected are noted with an [S,d]. -
The representative region used for the large dairy is Tulare County, California.
The model farm is assumed to have 1,450 cows, 435 heifers, and 435 calves in free stalls. The
farm is evaluated for both a covered lagoon digester and a complete mix digester.
Based on the input data provided, FarmWare calculates the influent and effluent
waste to and from the digester and the specific design and operating parameters. For the large
dairy, the FarmWare model calculates a total manure generation of about 187,000 Ib/day. With
an average volatile solids (VS) production of 8.5 Ib/day per 1,000 pounds of animal, the
FarmWare program estimates a total VS production of about 18,000 Ib/day. The model also
generates the design specifications for each system as shown in Table 5.13.2-2.
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A complete mix digester is a heated, constant volume, mechanically-mixed tank
with a gas-impermeable collection cover. Manure waste is preheated and added daily to the
digester, where it is intermittently mixed to prevent formation of a crust and to keep solids in
suspension. Average manure retention times range from 15 to 20 days. The gas-tight cover
maintains anaerobic conditions inside the tank and collects the biogas through attached pipes.
The heat generated by burning the collected biogas is used to heat the digester (USEPA, 1997a).
A covered lagoon digester is the simplest type of methane recovery system. This
digester consists of two basins, one of which is topped with a gas-impermeable cover. This
floating impermeable cover is typically made of high density polyethylene (HDPE) or
polypropylene. The cover may be designed as a "bank-to-bank" cover, which spans the entire
lagoon surface with a fabricated floating cover, or as a "modular" cover, in which the cover
comprises smaller sections. Biogas collects under the cover and is recovered for use in generating
electricity. The second basin is uncovered and is used to store effluent from the digester. Often.,
manure waste is treated through a solids separator prior to the covered lagoon digester to ensure
the solids content is less than 2 percent (USEPA, 1996).
Selection of the type of digester is dictated by the percent solids expected hi the
manure waste. To estimate the costs for a digester system, dairies that operate flush cleaning
systems are assumed to use a covered lagoon system following a settling basin, while dairies that
operate scrape systems are assumed to use a complete mix digester following a settling basin.
The design of the digester and methane recovery system is based on the AgSTAR FarmWare
model (EPA, 1997a). The design and cost of the concrete settling basins are discussed hi Section
5.2.
5.13.2
Design
Dairy
Inputs to the FarmWare model are based on the model farm characteristics for a
large dairy. The FarmWare model requires input data on the livestock type, number of animals,
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5.13.1
Technology Description
Anaerobic digestion is the decomposition of organic matter in the absence of
oxygen and nitrates. Under these anaerobic conditions", the"brganic material is stabilized and is
converted biologically to a range of end products, including methane and carb'on dioxide.
Anaerobic treatment reduces BOD* odor, and pathogens, and generates biogas (methane) that can
be used as a fuel.- The methane-rich gas produced during digestion may-be collected as a source
of energy to offset the cost of operating the digester. Liquid and sludge from the system are
applied to on-site cropland as fertilizer or irrigation water, or are transported off site
'Anaerobic digesters are specially designed tanks or concrete basinTthat can
anaerobically decompose volatile solids in the manure to produce biogas. Manure and/or process
wastewater may be routed to these digesters for storage and treatment. Depending on the waste
characteristics, one of the following main types of artaerpbic digesters may ie used:;
Plug flow;
Complete mix; and
Covered lagoon. ,
Plug flow digesters are applicable for treating wastes with high (>10 percent) solids content, while
covered lagoons are appropriate for treating wastes with low (<2 percent) solids content.
Complete mix digesters are used for treating wastes with a solids content between 2 and 10
percent. The plug flow and the complete mix digesters are applicable in virtually all climates as
they use supplemental heat to ensure optimal temperature. Covered lagoons generally do not use
supplemental heat and are most effectively used in warmer climates (USEPA, 1996).
A plug flow digester is a constant volume, flow-through long tank with a gas-
impermeable expandable cover. Manure waste is added to the digester daily, slowly pushing the
older manure plugs through the tank. Average manure retention times range from 15 to 20 days.
The gas-impermeable cover maintains anaerobic conditions inside the tank and collects the biogas
through attached pipes (USEPA, 1997b).
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At poultry operations, annual costs include both operation and maintenance costs.
It is assumed that a sufficient supply of amendments is available on site. EPA estimates that
mortality transportation, loading, and turning in compost bins requires 90 hours per year. The
value of tractor usage is $30/hour, and the labor rate is set at $10/hour. The capital cost of the
mortality composting facility is multiplied by .02 to estimate the annual maintenance cost of the
facility. The total annual cost for mortality composting is therefore determined from the following
equation:
Annual Cost = 90 x (30 + 10) + .02 x Capital Cost
5.12.4
Results
model farm.
5.13
Appendix A, Table A-15 presents the cost model results for composting at each
Anaerobic Digestion with Energy Recovery
Anaerobic digesters are sometimes used at animal feeding operations to
biologically decompose manure while controlling odor and generating energy. In the United
States, as of 1998 there were about 94 digesters that were installed or were planned for working
dairy, swine, and caged-layer poultry operations (Lusk, P., 1998). Of these 94 digesters, more
than 60 percent of plug flow and complete mix digesters and 12 percent of the covered lagoon
digesters have failed (Lusk, P., 1998). Many of these failures were of systems constructed prior
to 1984; since that time, more simplified digester designs have been implemented, which have
greatly improved reliability. Very few dairies in the United States have operable digesters with
energy recovery.
Anaerobic digestion with energy recovery is used as the cost basis for Option 6.
Under this option, only large dairies and large swine operations are costed for installation of an
anaerobic digester, with energy recovery system. ;
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The total capital cost for mortality composting structures varies with the size of
the operation, and is calculated as follows:
Capital Cost = Mortality Volume x $7.50 per square foot.
5 ft depth
Total Annual Costs
The volume of wheat straw required is used to determine the cost of the
composting amendments. The total volume of the compost pile is used to calculate the labor
costs for turning. The following equation is used to calculate the composting annual costs
(Sweeten, J.M. and S.H. Amosson, 1995):
Annual Cost = ($2.69/ton x Volume,.,,,,,.,.,^) + ($72.68/ton x VolumewhK1,sllaw) +
($1.75/100cf x Volume^,) - ($1.70 x Selling Weight/2000)
where:
Volumecolleoted
Volumewheatstraw=
$1.75
Volumewater
$1.70
Selling weight
= Volume of manure collected for compost
Volume of wheat straw added to balance carbon/nitrogen
ratio
= Cost of water per 100 cubic feet
= Volume of water added to mixture
= Net value of compost as a fertilizer, subtracting
value of manure as fertilizer (Sweeten, J.M. and
S.H. Amosson, 1995)
= Final composted weight of manure mixture.
Manure solids are expected to be reduced after composting; however, with the
addition of the carbon amendments, the weight of compost to be transported or land applied is
not significantly different than that manure that is not composted. The cost model calculates these
differences, however, and considers them in calculating transportation costs, described in Section
5.9.
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Table 5.12.3-1
Unit Costs for Composting
Unit
Windrow turning equipment
(Valoraction 5 1 0 rotary drum turner
tractor attachment)
Thermometers
Turning labor
Water
Value of manure fertilizer
(based on nitrogen and phosphorus)
Value of composted manure
(based on nitrogen and phosphorus)
Cost (1997)
. $8,914
$242.27 (for set of two)
$2.69/ton
$0.00203 per gallon
$4.99 per ton
$6.69 per ton
$72.68/ton
Source
On-Farm Composting Handbook,
NRAES-54
Omega Engineering
On-Farm Composting Handbook,
NRAES-54
EPA, Technical Development
Document for Metal Products and
Machinery Effluent Limitation
Guidelines, in progress.
Manure Quality and Economics, J.M.
Sweeten, S.H. Amosson, and B.W.
Auverman.
Case's Agworld.com
Capital costs for mortality composting are calculated assuming a depth of 5 feet.
Then, the square footage of the composting facility is calculated from the volume. The cost
model uses a construction cost of $7.50 per square foot for mortality compost facilities, based on
the price of a poultry drystack/composter with concrete floor and wooden walls (USDA NRCS,
2002a). The capital cost is determined with the following equation:
Capital Cost = MortVolume -*• 5 x 7.50
Total Capital Costs
The following equation is used to calculate the windrow composting capital cost:
Capital Cost = Windrow Turning Equipment + Thermometers
= $8,914 + $242.27
The total capital costs for windrow composting is $9,156.27.
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Compost Recipe
As stated in Section 5.12.1, manure must be mixed with composting amendments
to obtain the proper C:N ratio and moisture content. The cost model assumes that wheat straw is
used as the composting amendment. Wheat straw has a moisture content of 10 percent and. a C:N
ratio of 130. Manure collected from drylots has a moisture content of 35.4 percent. The carbon
content is calculated from the volatile solids composition of manure. It is estimated that manure
has a volatile solids composition of 564.6 Ib/ton (Sweeten, J.M. and S.H. Amosson, 1995). The
carbon content is calculated using the following equation (USDA NRCS, 1996):
Carbon.
Volatile Solidsmanure = 564.6
1.8 1.8
= 314
The nitrogen content of manure is estimated to be 25.71 Ib/ton (Sweeten, J.M. and S.H.
Amosson, 1995). The carbon and nitrogen contents are converted to a percent basis. The C:N
ratio of the manure is calculated using the percent composition and the volume of manure. Wheat
straw and water are added to the compost mix until the C:N ratio is between 25:1 and 40:1 and
the moisture content is between 40 and 65 percent. The cost model simulates this method in the
composting cost module, performing an iteration to determine the proper mix of manure, wheat
straw, and water.
5.12.3
Costs
Capital costs for windrow composting include turning equipment and
thermometers to monitor the pile temperature. Annual costs include the labor to turn the pile and
any required composting amendment (hi this case, wheat straw and water). Additionally, EPA
assumes that operations would be able to recoup some costs of composting by selling composted
manure. EPA assumes that the cost recouped equals the difference between the selling price of
uncomposted manure and composted manure. Table 5.12.3-1 presents the 1997 unit costs for
these items.
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50 percent (see Section 5.1). For beef and heifer feedlots, the additional volume added to the
compost pile from the settling basin is the annual solids in runoff multiplied by the settling
efficiency.
Volume Reduction •
One of the major benefits of composting is waste volume reduction, which can
reduce transportation costs. Finished compost is estimated to contain 30.8 percent moisture
(Sweeten, J.M. and S.H. Amosson, 1995). This moisture content is used in the following
equation to determine the weight of finished compost:
Final Weight = Initial Weight x
(1 - Initial Moisture)
(1 - Final Moisture)
Mortality Composting for Swine and Poultry Operations
The volume needed for mortality composting includes the dead animals and the
other materials included in the compost mix. This mix of animals and compost ingredients is
addressed in the cost model by using the factor of 2 cubic feet per pound of dead bird in the
following equation:.
MortVolume = nohead * deadlen x deadwt x pctdead x 2 x 1.5
where:
MortVolume
Nohead
Deadlen
Deadwt
Pctdead
2
1.5
Total volume required, ft3
Number of animals
Lifespan of the animal, days/cycle
Market weight of the animal, Ibs/head
Mortality rate (%/cycle expressed as a decimal fraction)
Primary plus secondary storage cubic feet per pound of
dead animal (Barker, J.C., 2000)
Safety factor for catastrophic events.
5-115
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excreted manure is the same as in the collected manure, the volume of manure collected from the
drylot can be calculated using a mass balance on solids using the following equations:
Volume Solids roUccted = Volume SolidSe^ed
Volume Solids = Total Volume x ( 1 - Moisture) "
Volumecollected (1 - Moisture^^J = Volume^^ (1 - MoistureexcrctKl) ;' ''' '
Volumecollected =
..... "
1 - Moistureexcreted)]
- Molsturecolleoted)
! •:>• "'" The cost model estimates that manure collected from the drylot has a moisture
content of 35.4 percent (Sweeten, J.M. and S.H. Amosson, 1995). The values of the parameters
used to compute the volume of manure are contained in the manure reference table and cost run
information in the cost model, i ' , . .. t
Some of the manure solids that accumulate on drylots are lost in the runoff from
the feedlot before the waste is composted; therefore, the solids lost in runoff are subtracted from
the total volume of manure. The amount of solids lost in runoff is estimated at 1 .5 percent of the
total drylot runoff (MWPS, 1985).
Settling Basins
Option 5 A includes the addition of separated solids from the settling basin to the
compost pile. Because wastes from dairy flush barns have a high moisture content, they are
generally not composted; however, the settled solids from sedimentation basins can be added to
the compost pile. Therefore, a fraction of the manure from mature dairy cows barns is added to
the compost pile after some drying has occurred. For beef feedlots, only runoff enters the
sedimentation basins; therefore, a fraction of the solids entering the basin as runoff is added to the
compost pile.
For dairies, the cost model calculates the amount of separated solids by computing
the amount of manure generated in the barn and parlor and multiplying by the settling efficiency of
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Tractor
Windrow
Turning
Equipment
Figure 5.12.2-1. Windrow Composting
Drylots
The cost model assumes that all beef cattle, dairy calves, and heifers are kept on
drylots. Manure from drylots is periodically scraped and moved to the compost pile. The amount
of manure generated (as-excreted) is calculated using the information and equations in Section
4.6. The volume of manure collected from the drylot is less than the as-excreted volume because
the manure moisture content decreases on the drylot. Because the volume of solids in the as-
5-113
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Windrow Composting for Beef Feedlots, Dairies, and Heifer Operations
Windrow composting systems are designed for use at beef feedlots, heifer
operations, and dairies. Manure and other raw materials are formed into windrows and
periodically turned. The size and shape of the windrow depends on the type of turning equipment
used by the site. The cost model assumes that sites use a tractor attachment for turning made by
i '. ~:\r. ."'"'' - -
Valoraction, Incorporated (NRAES, 1992) (see Figure 5.12.2-1). This type of windrow turner
can turn windrows 10 feet wide by 4.2 feet tall. Windrow composting requires less labor and
equipment than other types of composting and allows greater flexibility with respect to location
and composting amendments.
Beef feedlots and heifer operations can compost the manure collected from the
drylots. Because dairies and veal operations use flush and hose systems, their waste is too wet for
composting. However, the manure from calves and heifers kept on drylots at dairies can be
composted. Separated solids from sedimentation basins can also be added to the compost pile.
A typical mortality composting facility consists of two stages, primary and
secondary (USDA NRCS, 1996). The. first stage consists of equally sized bins in which the dead
animals and amendments are initially added and allowed to compost. The mixture is moved from
the first stage to the second stage, or secondary digester, when the compost temperature begins to
decline. The second stage can also consist of a number of bins, but it is usually just one bin or
concrete area that allows compost to be stacked with a volume equal to or greater than the sum of
the first stage bins. The design volume for each stage should be based on peak disposal
requirements for the animal operation.
Volume of Manure .
The cost model calculates the volume of waste transferred to the compost pile
from drylots and from settling basins.
5-112
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with strong odors are produced. Aerating the pile also helps to remove excess heat and trapped
gases from the composting pile.
Composting time and efficiency are affected by the amount of oxygen, the energy
source (carbon) and amount of nutrients (nitrogen) in the raw materials, the moisture content, and
the particle size and porosity of the materials. The amounts of carbon, .nitrogen, and moisture
should be properly balanced in the initial compost mix. Moisture levels should be in the range of
40 to 65 percent. Water"is necessary "toTsupport biological activity; however, if the moisture
content is too high, water displaces air in the pore.spaces_and thej>ile can become anaerobic.
Moisture content gradually decreases during the composting period. -The carbon to nitrogen ratio
(C:N) should be between 20:1 and 40:1. If the C:N ratio is too low, the carbon is used before all
the nitrogen is stabilized and the excess nitrogen can volatilize as ammonia and cause odor
problems. If the ratio is too high, the composting process slows as nitrogen becomes the limiting
nutrient. Manure typically needs to be mixed with drier, carbonaceous material to obtain the
desired moisture and C:N levels.
The length of time required for composting depends on the materials used, the
composting management practices, and the desired compost characteristics. Composting is
judged to be complete by characteristics related to its use and handling such as C:N ratio, oxygen
demand, temperature, and odor. A curing period of about one month during which resistant
compounds, organic acids, and large particles are further decomposed, follows composting.
5.12.2
Design
The cost methodology for all considered options included windrow composting at
beef feedlots, dairies, and heifer operations. If the volume reduction resulting from composting
resulted in a more cost effective option, then composting was selected as a waste management
technology. The cost methodology for swine and poultry operations included mortality
composting under ground water options. Each of these composting methods are described below.
5-111
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50 percent (see Section 5.1). For beef and heifer feedlots, the additional volume added to the
compost pile from the settling basin is the annual solids in runoff .multiplied by the settling
efficiency.
Volume Reduction
One of the major benefits of composting is waste volume reduction, which can
reduce transportation costs. Finished compost is estimated to contain 30.8 percent moisture
(Sweeten, J.M. and S.H. Amosson, 1995). This moisture content is used in the following
equation to determine the weight of finished compost:
Final Weight = Initial Weight x
(1 - Initial Moisture)
(1 - Final Moisture)
Mortality Composting for Swine and Poultry Operations
The volume needed for mortality composting includes the dead animals and the
other materials included in the compost mix. This mix of animals and compost ingredients is
addressed in the cost model by using the factor of 2 cubic feet per pound of dead bird in the
following equation:.
MortVolume = nohead •*• deadlen x deadwt x pctdead x 2 x i .5
where:
MortVolume
Nohead
Deadlen
Deadwt
Pctdead
2
1.5
Total volume required, ft3
Number of animals
Lifespan of the animal, days/cycle
Market weight of the animal, Ibs/head
Mortality rate (%/cycle expressed as a decimal fraction)
Primary plus secondary storage cubic feet per pound of
dead animal (Barker, J.C., 2000)
Safely factor for catastrophic events.
5-115
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Compost Recipe
As stated in Section 5.12.1, manure must be mixed with composting amendments
to obtain the proper C:N ratio and moisture content The cost model assumes that wheat straw is
used as the composting amendment. Wheat straw has a moisture content of 10 percent and a C:N
ratio of 130. Manure collected from drylots has a moisture content of 35.4 percent. The carbon
content is calculated from the volatile solids composition of manure. It is estimated that manure
has a volatile solids composition of 564.6 Ib/ton (Sweeten, J.M. and S.H. Amosson, 1995). The
carbon content is calculated using the following equation (USDA NRCS, 1996):
Carbon.
Volatile Solidsmanure _ 564.6
1.8 ~ 1.8
= 314
The nitrogen content of manure is estimated to be 25.71 Ib/ton (Sweeten, J.M. and S.H.
Amosson, 1995). The carbon and nitrogen contents are converted to a percent basis. The C:N
ratio of the manure is calculated using the percent composition and the volume of manure. Wheat
straw and water are added to the compost mix until the C:N ratio is between 25:1 and 40:1 and
the moisture content is between 40 and 65 percent. The cost model simulates this method in the
composting cost module, performing an iteration to determine the proper mix of manure, wheat
straw, and water.
5.12.3
Costs
Capital costs for windrow composting include turning equipment and
thermometers to monitor the pile temperature. Annual costs include the labor to turn the pile and
any required composting amendment (in this case, wheat straw and water). Additionally, EPA
assumes that operations would be able to recoup some costs of composting by selling composted
manure. EPA assumes that the cost recouped equals the difference between the selling price of
uncomposted manure and composted manure. Table 5.12.3-1 presents the 1997 unit costs for
these items.
5-116
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Table 5.12.3-1
Unit Costs for Composting
•J'4- ••--..,;•>• • Unit' • "-.'': •'.'_'
Windrow turning equipment
(Valoraction 510 rotary drum turner
tractor attachment)
Thermometers
Turning labor
Water
Value of manure fertilizer
(based on nitrogen and phosphorus)
Value of composted manure
(based on nitrogen and phosphorus)
Wheat straw
, • ^Crtsft^SST)/,;--^'^-?
. $8,914
$242.27 (for set of two)
$2.69/ton
$0.00203 per gallon
j
$4.99 per ton
$6.69 per ton
$72.68/ton
•.;, ••- :...-• -. -_,,;.. S6u^;,.v*:e!;;; :',
On-Farm Composting Handbook,
NRAES-54
Omega Engineering
On-Farm Composting Handbook,
NRAES-54
EPA, Technical Development
Document for Metal Products and
Machinery Effluent Limitation
Guidelines, in progress.
Manure Quality and Economics, J.M.
Sweeten, S.H. Amosson, and B.W.
Auverman.
Case's Agworld.com
Capital costs for mortality composting are calculated assuming a depth of 5 feet.
Then, the square footage of the composting facility is calculated from the volume. The cost
model uses a construction cost of $7.50 per square foot for mortality compost facilities, based on
the price of a poultry drystack/composter with concrete floor and wooden walls (USDA NRCS,
2002a). The capital cost is determined with the following equation:
Capital Cost = MortVolume * 5 x 7.50
Total Capital Costs
The following equation is used to calculate the windrow composting capital cost:
Capital Cost = Windrow Turning Equipment + Thermometers
= $8,914+ $242.27
The total capital costs for windrow composting is $9,156.27.
5-117
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The total capital cost for mortality composting structures varies with the size of
the operation, and is calculated as follows:
Capital Cost = Mortality Volume x $7.50 per square foot.
5 ft depth
Total Annual Costs
The volume of wheat straw required is used to determine the cost of the
composting amendments. The total volume of the compost pile is used to calculate the labor
costs for turning. The following equation is used to calculate the composting annual costs
(Sweeten, J.M. and S.H. Amosson, 1995):
Annual Cost = ($2.69/ton x Volume^,,,,) + ($72.68/ton x VolumewheatsMW) +
($1.75/1 OOcfx Volume^) - ($1.70 x Selling Weight/2000)
where:
Volumecollected
Volumewheatstraw=
$1.75
Volumewater
$1.70
Selling weight
= Volume of manure collected for compost
Volume of wheat straw added to balance carbon/nitrogen
ratio
= Cost of water per 100 cubic feet
= Volume of water added to mixture
= Net value of compost as a fertilizer, subtracting
value of manure as fertilizer (Sweeten, J.M. and
S.H. Amosson, 1995)
= Final composted weight of manure mixture.
Manure solids are expected to be reduced after composting; however, with the
addition of the carbon amendments, the weight of compost to be transported or land applied is
not significantly different than that manure that is not composted. The cost model calculates these
differences, however, and considers them in calculating transportation costs, described in Section
5.9.
5-118
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At poultry operations, annual costs include both operation and maintenance costs.
It is assumed that a sufficient supply of amendments is available on site. EPA estimates that
mortality transportation, loading, and turning in compost bins requires 90 hours per year. The
value of tractor usage is $30/hour, and the labor rate is set at $10/hour. The capital cost of the
mortality composting facility is multiplied by .02 to estimate the annual maintenance cost of the
facility. The total annual cost for mortality composting is therefore determined from the following
equation:
Annual Cost = 90 x (30+10) + .02 x Capital Cost
5.12.4
Results
model farm.
Appendix A, Table A-15 presents the cost model results for composting at each
5.13
Anaerobic Digestion with Energy Recovery
Anaerobic digesters are sometimes used at animal feeding operations to
biologically decompose manure while controlling odor and generating energy. In the United
States, as of 1998 there were about 94 digesters that were installed or were planned for working
dairy, swine, and caged-layer poultry operations (Lusk, P., 1998). Of these 94 digesters, more
than 60 percent of plug flow and complete mix digesters and 12 percent of the covered lagoon
digesters have failed (Lusk, P., 1998). Many of these failures were of systems constructed prior
to 1984; since that time, more simplified digester designs have been implemented, which have
greatly improved reliability. Very few dairies in the United States have operable digesters with
energy recovery.
Anaerobic digestion with energy recovery is used as the cost basis for Option 6.
Under this option, only large dairies and large swine operations are costed for installation of an
anaerobic digester, with energy recovery system.
5-119
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5.13.1
Technology Description
Anaerobic digestion is the decomposition of organic matter in the absence of
oxygen and nitrates. Under these anaerobic conditions, the "organic material is" stabilized and is
converted biologically to a range of end products, including methane and carbon dioxide.
Anaerobic treatment reduces BOD, odor, and pathogens, and generates biogas (methane) that can
be used as a fuel. The methane-rich gas produced during digestion may be collected as a source
of energy to offset the cost of operating the digester. Liquid and sludge from the system are
applied to on-site cropland as fertilizer or irrigation water, or are transported off site.
Anaerobic digesters are specially designed tanks or concrete basins "that can
anaerobically decompose volatile solids in the manure to produce biogas. Manure and/or process
wastewater may be routed to these digesters for storage and treatment. Depending on the waste
characteristics, one of the following main types of anaerobic digesters may J>e used:
Plug flow;
Complete mix; and
Covered lagoon.
Plug flow digesters are applicable for treating wastes with high (>10 percent) solids content, while
covered lagoons are appropriate for treating wastes with low (<2 percent) solids content.
Complete mix digesters are used for treating wastes with a solids content between 2 and 10
percent. The plug flow and the complete mix digesters are applicable in virtually all climates as
they use supplemental heat to ensure optimal temperature. Covered lagoons generally do not use
supplemental heat and are most effectively used in warmer climates (USEPA, 1996).
A plug flow digester is a constant volume, flow-through long tank with a gas-
impermeable expandable cover. Manure waste is added to the digester daily, slowly pushing the
older manure plugs through the tank. Average manure retention times range from 15 to 20 days.
The gas-impermeable cover maintains anaerobic conditions inside the tank and collects the biogas
through attached pipes (USEPA, 1997b).
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A complete mix digester is a heated, constant volume, mechanically-mixed tank
with a gas-impermeable collection cover. Manure waste is preheated and added daily to the
digester, where it is intermittently mixed to prevent formation of a crust and to keep solids in
suspension. Average manure retention times range from 15 to 20 days. The gas-tight cover
maintains anaerobic conditions inside the tank and collects the biogas through attached pipes.
The heat generated by burning the collected biogas is used to heat the digester (USEPA, 1997a).
A covered lagoon digester is the simplest type of methane recovery system. This
digester consists of two basins, one of which is topped with a gas-impermeable cover. This
floating impermeable cover is typically made of high density polyethylene (HDPE) or
polypropylene. The cover may be designed as a "bank-to-bank" cover, which spans the entire
lagoon surface with a fabricated floating cover, or as a "modular" cover, in which the cover
comprises smaller sections. Biogas collects under the cover and is recovered for use in generating
electricity. The second basin is uncovered and is'used to store effluent from the digester. Often,
manure waste is treated through a solids separator prior to the covered lagoon digester to ensure
the solids content is less than 2 percent (USEPA, 1996).
Selection of the type of digester is dictated by the percent solids expected in the
manure waste. To estimate the costs for a digester system, dairies that operate flush cleaning
systems are assumed to use a covered lagoon system following a settling basin, while dairies that
operate scrape systems are assumed to use a complete mix digester following a settling basin.
The design of the digester and methane recovery system is based on the AgSTAR FarmWare
model (EPA, 1997a). The design and cost of the concrete settling basins are discussed in Section
5.2.
5.13.2
Design
Dairy
Inputs to the FarmWare model are based on the model farm characteristics for a
large dairy. The FarmWare model requires input data on the livestock type, number of animals,
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geographic location, method of manure collection, and the type of waste management system.
Table 5.13.2-1 summarizes the inputs used for both the covered lagoon and complete mix
digesters. User-selected input values are noted with the letter "S" in brackets, [S]. Default input
values that are selected are noted with an [S,d].
The representative region used for the large dairy is Tulare County, California.
The model farm is assumed to have 1,450 cows, 435 heifers, and 435 calves in free stalls. The
farm is evaluated for both a covered lagoon digester and a complete mix digester.
Based on the input data provided, FarmWare calculates the influent and effluent
waste to and from the digester and the specific design and operating parameters. For the large
dairy, the FarmWare model calculates a total manure generation of about 187,000 Ib/day. With
an average volatile solids (VS) production of 8.5 Ib/day per 1,000 pounds of animal, the
FarmWare program estimates a total VS production of about 18,000 Ib/day. The model also
generates the design specifications for each system as shown in Table 5.13.2-2.
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Table 5.13.2-1
Farm Ware Input Table
: Input Data
• Type of Digester
Covered Lagoon Digester
Climate Data
County, State
Rainfall
Recommended Minimum Lagoon
Hydraulic Retention Time
Recommended Maximum Lagoon Loading
25-yr, 24-hr Storm
Annual Runoff Unpaved
Annual Runoff Paved
Annual Evaporation
- CompleteTVKx Digester
Tulare, California [S]
Determined by Farm Ware [S,d]
42 days '
101bVS/l,OOOcuft
3.5
inches
23 % of precipitation
50% of precipitation
55 inches
Farm Type
Farm Type
Farm Size (Farm Number)
Manure Collection Method
Waste Treatment System
Pretreatment
Dairy: Freestall [S]
1,450 milking cows [S]
435 heifers [S]
435 calves [S]
Flush parlor/
Flush freestall barn [S]
Flush parlor/
Scrape freestall barn [S]
Methane recovery lagoon [S]
Settling basin [S]
NA
[S] = User selected input.
[d] = Default input.
NA - Not applicable.
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Table 5.13.2-2
FarmWare Design Information
Design Information
•.'' • _•-.•: .;. • ..•;...-. •;•••••:<•. - 2 Type of Digester .. • • ;.-,; .'•• - ; -";
Covered Lagoon JDigester :•[.
, Complete Mix Digester •
Waste Characteristics
Amount of Influent Manure (Ib)
Rainfall (Ib)
Amount Digested (Ib)
Effluent (Ib)
1,656,696
14,883
23,642
' 1,647,937
239,325
NA
76,285
163,040
Design Parameters < ; ;• '• ' -i« . ••'
Hydraulic Retention [Time (days)
Depth (ft)
Dimension (ft)
Freeboard (ft)
Slope (hor/ver)
Total Volume (ft3)
.42
20
285 x 285
. - ,„ , 'i
2
1,21-1,167. \
20 .
20
73 diameter
1
NA
84,272
NA- Not applicable.
5.13.3
Costs
FarmWare calculates the cost to construct the digester, with or without energy
recovery equipment. Option 6 costs were calculated including the cost for energy recovery
equipment, the cost for water use, as well as an additional 15 percent of the capital costs
estimated by FarmWare to account for contingency items.
The biogas that is collected during the digestion process may be used to produce
electricity and propane. FarmWare allows the user to assign a unit value for electricity to estimate
the amount of cost savings the farm would receive by recovering biogas for energy use. For
Option 6 costs, a national average unit price for electricity of 7.4 cents per kilowatt hour (kWh) is
used (USDOE, 1998).
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The .model also allows the user to assign a dollar value for benefits such as odor
and pathogen reduction. For the Option 6 costs, no dollar value is assigned for these benefits.
Large Dairy - Covered Lagoon System
For this analysis, it is assumed that the cows spend 4 hours per day in the milking
parlor and 20 hours per day in the barn, and the heifers and calves spend 24 hours per day in
drylots. The milking parlor and the barn use a flush system for manure removal, and the
wastewater is sent to a covered anaerobic lagoon through a settling basin. The manure from the
feed apron and the drylots is scraped and applied to cropland.
. The total lagoon digester volume is calculated to be about 1,200,000 cubic feet.
With a lagoon depth of 20 feet, the linear surface dimensions are estimated to be 285 feet by 285
feet, representing a total area of about 81,225 square feet that requires an industrial fabric cover,
such as an HDPE cover. Table 5.13.2-2 presents the design information for the covered lagoon
digester, as determined by the FarmWare model.
The capital cost of a primary digester lagoon with cover is $ 111,000 and the
engine generator is $80,000. Other engineering costs total $25,000. The total capital cost is
$216,000. Annual costs include the FarmWare estimated operating savings, water costs for
dilution water, and an estimated 15 percent of the total capital costs. The net annual operating
cost is estimated to be ($63,994) per year (i.e., a net savings). This annual operating cost does
not reflect additional potential decreases in transportation costs, due to the reduction in solids a
digester causes. (Transportation costs are considered in Section 5.9 of this report).
Large Dairy - Complete Mix Digester System
For this analysis, it is assumed that the cows spend 4 hours per day in the milking
parlor, which uses a flush system for manure removal and 20 hours per day in the freestall barn,
and the heifers and calves spend 24 hours per day in drylots. The wastewater from the milking
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parlor goes through a mix tank before going to the complete mix digester. The manure in the
freestall barn and the drylots is scraped and applied to cropland.
The total digester volume is calculated to be about 84,000 cubic feet. With a
digester depth of 20 feet, the diameter is estimated to be 73 feet, with a total area of 4,200 square
feet. Table 5.13.2-2 presents the design information for the complete mix digester, as determined
by the FarmWare model.
The capital costs for the complete mix digester is $127,000, the mix tank is
$26,000, and the engine generator is $187,000. Other engineering costs total $25,000. The total
capital cost is $364,857. Annual costs include the FarmWare estimated operating savings, water
costs for dilution water, and an estimated 15 percent of the total capital costs. The net annual
operating cost is estimated to be ($85,969) per year (i.e., a net savings). This annual operating
cost does not reflect potential decreases in transportation costs, due to the reduction in solids a
digester causes. (Transportation costs are considered in Section 5.9 of this report.)
Swine Operations
The capital and annual costs for digesters were determined from the following two
equations using data from Table 5.13.3-1:
Capital Cost = nohead x capheadcost
Annual Cost = nohead x annheadcost
where:
Nohead =
Capheadcost =
Annheadcost =
Number of animals
Capital cost per animal
Annual cost per animal.
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Table 5.13.3-1
Digester Costs for Swine
I Manure Type
Pit
Liquid
Evaporative Pond
Operation Type
Grower-Feeder
Grower-Feeder
Farrow-Feeder
Farrow-Feeder
Grower-Feeder
Grower-Feeder
Farrow-Feeder
Farrow-Feeder
Grower-Feeder
Farrow-Feeder .
Region
Mid-Atlantic
Midwest
Mid-Atlantic
Midwest
Mid-Atlantic
Midwest
Mid-Atlantic
Midwest
Central
Central
Capital Cost
($ per Head)
41.3
42.1
39.09
39.37
38.73
39.45
33.81
34.79
37.62
33.81
Annual Cost *
(&per Head)
-6.3.1
-5.77
-2.08
-2.42
-6.18
-5.57
-1.97
-2.13
-5.55
-2.13
5.13.4
Results
Appendix A, Table A-16 presents the cost model results for constructing anaerobic
digesters with methane recovery at large dairies.
5.14
Litter Storage Sheds
Litter storage is included in the costing for all dry poultry operations.
Requirements for poultry litter storage structures are similar to those for mortality composting
facilities in that they require a roof, foundation and floor, and suitable building materials for side
walls. Storage facilities are assumed to be 68 feet wide and 8 feet tall. Litter is assumed to be
stacked to the top in a trapezoidal pile 48 feet wide at the base and 32 feet wide at the top.
There are aisles 10 feet wide on either side of the stack. It is assumed that poultry litter storage
facilities include a roof with a 0.75 pitch, a concrete floor 16 feet wide, and a 12-foot height from
floor to roof (NCSU, 1998). The width and height were designed for piling manure to its angle of
repose to minimize space. The length of the structure is variable.
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The size of a poultry manure storage facility was calculated based on the volume
of both manure and litter produced from the various poultry operations. Manure production for
all poultry types, when designing manure storage facilities, was assigned a value of 0.00169 ft3 per
bird per day (or 0.6169 ft3 per bird per year) (NCSU, 1998). The basic equation for calculating
manure production is:
where:
VolumeManure
Nohead
365
VolumeMmure = 0.00169 x Nohead x 365
Annual volume of manure, ft3
Number of animals
Days in year.
Litter production was calculated as the number of houses (25,000 chickens or
6,250 turkeys per house) multiplied by the shaving material application depth (3.0 inches),
multiplied by the area of the house (16,000 ft2), adjusted for the amount of house floor area to
receive shavings (zero percent for layers, 33 percent for pullets, and 100 percent for the remaining
poultry types), and multiplied by the frequency of litter storage emptying (no more than two times
per year). The basic equation for calculating litter production is:
where:
VolumeLitu.r = Houses x Depthstavings x AreaHouse x Coverage
Volume,^ =
Houses =
Depthshavings =
Coverage
Volume of litter in houses, ft3
Number of animal houses
Depth of litter, ft
Area of house floor, ft2
Portion of floor covered with litter (decimal fraction).
The volumes of manure and litter production are summed to arrive at the total
volume produced annually. The cost model assumes storage for six months. The volume of
storage required for the facility is calculated from the following:
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Volumestorage = (VolumeLitter + VolumeMamire) x Duration - 12
where:
Volume
Duration
12
'Storage
Storage facility volume
Time period for storage (months)
Months per year.
Assuming a height of 8 feet, the square footage of the litter storage facility is
calculated from the volume. EPA uses a construction cost of $8.50 per square foot based upon
the cost of a structure with concrete floors and walls since there is a risk of spontaneous
combustion at a stacking height of 8 feet (USDA NRCS, 2002a). The capital cost is determined
from the following equation:
Capital Cost =Volumestorage H- g x 8.50
The cost model includes no operating cost for storage facilities since manure and
litter management are considered part of the baseline scenario. Appendix Tables 17a through 17c
present capital costs for storage at dry poultry operations.
5.15
Lagoon Covers
The cost of lagoon covers is estimated as a technology that complies with Option 5
for Category 2 and 3 swine, layer, and veal operations. Flares are added to covered lagoons for
swine and poultry operations. In addition to covering lagoons under Option 5, evaporative pond
systems at swine operations are assumed abandoned and replaced with a new covered lagoon and
berms. These new lagoons are designed for a volume that does not include direct precipitation
since they are covered. Berms are not constructed around the abandoned evaporative pond. For
wet layer operations, lagoons for egg washing waste are also covered, but flares are not added.
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Design
As discussed in Section 5.4, lagoon shape is assumed to approximately be a
frustrum with top length and width equal and bottom length and width equal. Lagoon cover size
is estimated as the square footage of the top surface of the lagoon. Lagoon cover size is
calculated as:
Cover - W,agoc,ntopx L,agoomop
where:
W,
lagoontop
igoontop
Width of top of lagoon or evaporative pond, ft
Length of top of lagoon or evaporative pond, ft.
Lagoons for egg wash water at wet layer operations are designed to provide
storage for six months in accordance with the procedure described in Section 5.4.5 for swirie and
poultry operations. The volume required for egg wash water is determined from the following
equation:
where:
Nohead
0.05776
= Nohead x 0.057756619
Number of layers
Egg wash water volume per head per 6 months.
Layers produce an average of 256 eggs per year (USDA NASS, 1998). A value of
4.6 liters per case is used based upon the quantity of wash water used for table eggs (Hamm, D.,
G. Searcy, and A. Mercuri. 1974). There are 360 eggs per case.(United Egg, 2002), so
0.000451238 cubic feet of water is used per egg (4.6/360 x 0.03531435 cubic feet/liter). Since
storage is for six months, the volume of egg wash water per head is 0.05776 (256 x 0.000451238
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Fixed One-Time Costs
Several lagoon cover manufacturers were contacted to identify costs of purchasing
and installing lagoon covers. The results of the survey are shown'in Table 5.15-1. Installed
lagoon covers range from $1.20 to $4.81 per square foot, with lower costs per square foot
expected at larger installations and depending upon whether insulation is required. Thus, to
develop costs for installation of insulated lagoon covers, a cost of $4.00 per square foot was
assumed. The capital cost of a flare is estimated to be $2,500, and the cost for a cover and flare is
calculated using the following equation:
Capital Cost = Area of Cover * $4/ft2 + $2,500
Table 5.15-1
Manufacturer-Suggested Costs of Lagoon Covers for Vz-Acre Lagoons
x:-r'"-v , Dealer -..
Lange Containment
Systems, Inc.
CWNeal
Environmental
Fabrics, Inc.
Reef Industries
Geomembrane
Technologies, Inc.
Environmental
Protection Inc.
>;;. —;/••; . '•• Descriptipji ; .-;• ••;..• '••^- x.v*'1
30 mil PVC liner, 36 mil reinforced Hypalon cover system
installation
'/4-acre lagoon, 32-mil polypropylene, installed
'/•j-acre lagoon, 40 mil HOPE uninsulated cover, gas, and rain .
collection
'/i-acre lagoon, 40 mil HPDE R-6 insulated cover, gas, and
rain collection
Permalon®, ply X-210 reinforced floating cover system (not
including foam float logs)
Vi-acre cover system installed, 30 mil reinforced modified
PVC layer (XR-5) and '/2-inch sublayer
36 mil reinforced cover
:• -^iCfist — V'.V
$1.28/ft2
$34,665
$3-4/ft*
$0.85/ft2
$2.25/ft2
$0.407^
$105,000
$0.45 - $0.50/ft2
Annual Costs
Operation and maintenance costs for lagoon covers were estimated at 2 percent of
capital costs. Appendix Table A-18 presents costs for lagoon covers at veal operations.
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5.16
Feeding Strategies
Feeding strategies designed to reduce nitrogen (N) and phosphorus (P) losses
include more precise diet formulation, enhancing the digestibility of feed ingredients, genetic
enhancement of cereal grains and other ingredients resulting in increased feed digestibility and
improved quality control. These strategies increase the efficiency with which the animals use the
nutrients in their feed and decrease the amount of nutrients excreted in the waste. With a lower
nutrient content, more manure can be applied to the land and less cost is incurred to transport
excess manure from the farm. Strategies that focus on reducing P concentrations, thus reducing
overapplication of P and associated runoff into surface waters, can turn manure into a more
balanced fertilizer in terms of plant requirements.
5.16.1
Technology Description
Feeding strategies that reduce nutrient concentrations in waste have been
developed for specific animal sectors, and those for the swine and poultry industries are described
below. The application of these types of feeding strategies to the beef industry has lagged behind
other livestock sectors and is not discussed here.
Swine
Lenis and Schutte (1990) showed that the protein content of a typical Dutch swine
ration could be reduced by 30 grams per kilogram without negative effects on animal
performance. They calculated that a 1-percent reduction in feed N could result in a 10-percent
reduction in excreted N. Monge et al. (1998) confirmed these findings by concluding that a 1-
percent reduction in feed N yielded an 11-percent reduction in excreted N. Experts believe that N
losses through excretion can be reduced by 15 to 30 percent in part by minimizing excesses in diet
with better quality control at the feed mill (NCSU, 1998).
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Poultry
Precision nutrition entails formulating feed to meet more precisely the animals'
nutritional requirements, causing more of the nutrients to be metabolized, thereby reducing the
amount of nutrients excreted. For more precise feeding, it is imperative that both the nutritional
requirements of the animal and the nutrient yield of the feed are fully understood. Greater
understanding of poultry physiology has led .to the development of computer growth models that
take into account a variety of factors, including strain, sex, and age of bird, for use in
implementing a nutritional program. By optimizing feeding regimes using simulation results,
poultry operations can increase growth rates while reducing nutrient losses in manure.
Phytase can be used to feed all-poultry. Phosphorus reductions of 30 to 50 percent
have been achieved by adding phytase to the feed mix while simultaneously decreasing the amount
of inorganic P normally added (NCSU, 1999). Addition of phytase to feed significantly reduces P
levels in poultry manure. The high cost of phytase application equipment has discouraged more
widespread use. Phytase is in use at many poultry operations.
5.16.2
Costs
The cost model applies feeding strategies to all Category 2 and 3 swine and
poultry operations under all options. Hauling costs are compared for the cases with and without
feeding strategies under a range of technology scenarios, including separators, retrofit scraper
systems, sludge cleanout, highrise hog houses, hoop houses for hogs, and lagoon covers.
The basic approach to estimating the costs of feeding strategies involves six steps:
1. Determine P-based and N-based feeding strategy costs for animal type;
2. Determine the quantity of N and P in the applied manure;
3. Determine the acreage required to spread manure under N-based or P-
based management;
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4: Determine the quantity of nutrient in excess of on-farm needs;
5. Determine hauling costs; and
6. Add hauling costs to feeding strategy costs.
Feeding Strategy Costs
Feeding strategy costs for both swine and poultry are provided in Table 5.16.2-1
(Tetra Tech, 2000c). EPA estimates that it costs $ 10 per ton ($0.005 per pound) to reduce
nitrogen in feed. It is assumed that layers consume the same quantity of feed per day as do
broilers, which consume 11 pounds of feed, costing $0.055, to achieve market weight. Since
broiler turnover is 5.5 flocks per year, versus 1 flock per year for layers, the quantity of feed for
layers is estimated as 5.5 x 11, bringing the cost to $0.3025 per layer (5.5 x 0.055). Turkeys
consume 46 pounds of feed, at a cost of 46 * 0.005, or $0.23 per turkey.
Phosphorus feeding strategy costs for"broilers and layers" are-assumed to be zero
since integrators supply the feed to the growers, and phytase is commonly used at these
operations. The cost of phytase js estimated at $1 per ton, or $0.0005 per pound. For turkeys,
the feeding cost is therefore 46 x 0.0005, or.$0.023 per turkey.
Table 5.16.2-1
Feeding Strategy Costs for Swine and Poultry
Animal
Broiler
Layer
Turkey
Pig - FF
Pig-GF
Turns
5.5
1
2.5
2.1
2.8
Feeding Strategy Costs ($ Per Animal)
N -Strategy
0.055
0.3025
0.23
2.70
2.70
P Strategy
0
0
0.023
0.36
0.36
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Feeding costs are calculated using the following equations:
where:
Swine - P-Based: CostFS = Noheadx UnitCost x Turns x o.7
Other: CostFS = Nohead x" UnitCost x Turns
CostFS
UnitCost
Turns
Cost of feeding strategies
Cost per animal for feeding strategy (Table 5.16.2-1)
Number of flocks or turnovers per year (Table 5.16.2-1).
Quantity of Nutrients Applied
Implementation of feeding strategies reduces the quantity of nutrients excreted.
The cost model assumes a 40-percent reduction in phosphorus excretion and a 20-percent
reduction in nitrogen excretion under P-based and N-based feeding strategies, respectively. The
following equation is used to calculate nutrient production resulting from feeding strategy
implementation:
where:
Nutrientps
Nutrient
Reduction
NutrientFS = Nutrient x (1-Reduction)
Total nutrient (N or P) in manure under feeding strategies
Total nutrient (N or P) in manure without feeding strategies
Feeding strategy nutrient reduction (N or P).
Acreage Required for Spreading
The acreage required to spread manure is calculated based upon nutrient content
of the manure, nutrient losses occurring during transport of the manure to the field, crop uptake
of the nutrient, and the portion of manure given away by the operation. The cost model assumes
that all nutrients are available to the crops, which is a conservative estimate with regard to
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I
acreage requirements. The values for nutrient uptake by crops are given in Table 5.16,2-2 (Tetra
Tech, 2000c). The following equation is used to determine the acreage required for spreading:
AcreageFS = NutrientFS x Efficiency x (1-Given) t Uptake
where:
AcreageFS
Nutrientpg
Efficiency
Given
Uptake
Acreage required to spread manure under feeding strategies,
acres
Total nutrient (N or P) hi manure under feeding strategies,
pounds per year
Portion of nutrient (N or P) available to crop, decimal
fraction =1 <
Portion of manure given away, decimal fraction
Crop uptake of nutrient (N or P), pounds per acre per year
(Section 4.9).
Table 5.16.2-2
Crop Nutrient Uptake
Animal Type
Poultry
Swine
Region
Mid-Atlantic
Midwest
South
Central
Mid-Atlantic
Midwest
N Uptake
(pounds per acre per year)
183
141
141
185
138
198
P Uptake
(pounds per acre per year)
20
10
10
24
14
19
Excess Nutrients
The cost model assumes that nitrogen feeding strategies are used under N-based
management, while phosphorus feeding strategies are used under P-based management. Excess
nutrients result when the acreage required to spread the manure at either N-based or P-based
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agronomic rates exceeds the acreage available at the operation. The cost model requires hauling
for cases where there are excess nutrients. The following equation is used to calculate the
quantity of excess nitrogen and phosphorus under P-based management where phosphorus
feeding strategies are employed: •
where:
ExcessN = NNoFS x (1- AcreageFaim ^-AcreageFS.P) x (l-Given)
Excessp = (PFS - PFarm) x (1 -Given)
Exces^ = Excess nitrogen, Ib/yr
Excessp = Excess phosphorus, Ib/yr
N = Nitrogen in manure without feeding strategies, Ib/yr
= Phosphorus in manure with feeding strategies, Ib/yr
= Phosphorus required on farm to meet crop nutrient
-. requirements, Ib/yr
AcreageFann = Acreage on farm available to spread manure, acres
AcreageFS.P = Acreage required to spread manure under P feeding
strategies, acres
Reduction = Feeding strategy nutrient reduction (N or P)
Given = Portion of manure given away, decimal fraction.
NoFS
FS
A similar set of equations is used to determine excess nitrogen and phosphorus
amounts under N-based nutrient management. In simple terms, the amount of manure spread on
the farm is based upon the quantity of the target nutrient (N or P) available in the manure after
feedings strategies for that nutrient are implemented. The nutrients in the leftover manure are
considered excess nutrients.
Hauling Costs
Hauling costs are determined using the basic approach described for contractor
hauling costs in Section 5.9.2. The portion of manure to be hauled is determined from the
following equation:
HauIPct= l-(AcreageFaim^- AcreageFS)
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where:
HaulPct
AcreageFanl
AcreageFS
Portion of manure hauled away, decimal fraction
Acreage on farm available to spread manure, acres
Acreage required to spread manure under (N or P) feeding
strategies, acres.
The quantity of manure to be hauled is calculated from the following equations for
liquid and solid manure:
where:
Liquid: VolumeLiquidMamirc = VolumeManure x HaulPct x (1-Given) x (1-Mangive)
Solid: WeightSolidMamTC= WeightManurc x HaulPct x (l-Given) x (1-Mangive)
VolumeLiquidManure
WeightSolidManure=
VolumeManure
WeightManure
Given
HaulPct
Mangive
= Annual volume of liquid manure to haul,
gallons/year
Annual weight of solid manure to haul, tons/year
= Annual volume of manure produced, gallons/year
= Annual weight of manure produced, tons/year
= Portion of manure given away, decimal fraction
= Portion of manure hauled away, decimal fraction
= Frequency factor for giving manure away.
EPA assumes that Category 3 operations incur no cost to haul manure under N-
based management since that is the baseline scenario. For all other Category 2 and 3 liquid-based
swine and poultry operations, the cost of hauling the sludge is determined using the following
equation:
lid= (Volumeu,uidManurx LiquidFirst) + (LiquidAdd x VolumeLiquidManur) x (Transport-1))
where:
CostLiquid
VolumeLiquidManu
LiquidFirst
LiquidAdd
Transport
Annual cost of hauling liquid manure
Annual volume of liquid manure to haul,
gallons/year
Liquid hauling cost for first mile
Liquid hauling cost beyond first mile
Transport distance for hauling manure.
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Transport distances are given in Table 5.9.2-1. For the Mid-Atlantic region, the
transport distances for liquid hauling are changed if feeding strategies are employed. If the
hauling percentage (HaulPct) is less than 20 percent (0.20), the transport distance is set at 5.5
miles, the distance for Nrbased management at Category 2 facilities (see Table 5.9.2-1).
Otherwise, the transport distance is set to 18 miles in the Mid-Atlantic region.
For all other Category 2 and 3 solid-based operations, the cost of hauling the
manure is determined using the following equation:
where:
CostSolid
WeightSoIidManure=
HaulRate
Transport
= WeightSolidManure x HaulRate x Transport
= Annual cost of hauling solid manure
Annual weight of solid manure to haul, tons/year
= Hauling rate based upon hauling distance (Table
5.17.3-3)
= Transport distance for hauling manure.
Total Feeding Strategy Costs
The cost model assessed the relative cost of feeding strategies by summing the
costs for feeding, strategies and the associated hauling. This cost can be compared versus hauling
without feeding strategies to determine which is less expensive. Similarly, hauling associated with
other nutrient reduction technologies (e.g., scraper systems) is costed with and without feeding
strategies. The total cost of feeding strategy implementation is estimated with the following
equation:
where:
CostFS
CostHauli
Cost = CostF<- + Cost,
•Hauling
Cost of feeding strategies
Cost of hauling with feeding strategies.
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5.17
Options to Retrofit Swine and Wet Layer Systems to Dry Systems
In addition to the use of lagoon covers to comply with the requirements of Option
5, EPA investigated retrofitting swine and wet layer systems to replace lagoons as the waste
management practice. Retrofitting to a "scraper system" was assessed for swine and wet layer
facilities. In addition, retrofitting to high-rise and hoop houses for swine operations was assessed.
The scraper system and high-rise house retrofit options require the cleanout and closure of the
existing lagoon.
5.17.1
Lagoon Cleanout and Closure Costs
Lagoon closures were used as part of the cost test for BAT option 5, and were
also considered as part of a proposed permit requirement to have a closure plan or a bond to
ensure closure. These options were not selected.
USDA NRCS developed an interim standard that has been use for closure of
lagoons used in North Carolina. NCDENR (1999) prepared a list of 65 lagoon closures that have
been cost-shared by the North Carolina Agriculture Cost Share Program. The smallest lagoon
was 0.11 acres, and the largest was 2.5 acres. The range of closure costs on a per acre basis was
generally in the $15K/acre to $60K/acre range. The average cost to clean out and close 65 dairy,
beef, poultry, and swine lagoons was $0.031 per gallon. This value is used to estimate the cost of
lagoon cleanout and closure nationally using the following equation:
Cleanout Cost = Volume*,
. x 0.031
where:
Volume
'Manure
Volume of manure for one year, gallons
Cleanout Cost = VolumeManure x 0.031
5-140
-------
Where,
VolumeManure = Volume of manure for one year (gallons)
5.17.2
Retrofit to Scraper System
Mechanical scrapers are dedicated to a specific alley, propelled by electrical
devices, and attached by cables or chains (USDA NRCS, 1996). Scrape alleys range from 3 to 8
feet wide for swine and poultry operations.
Scraper systems are applied to both swine and wet-layer facilities in the cost model
. One retrofit unit is required for each 1,250 hogs or 25,000 layers, with a minimum of one unit
per operation. Components of scraper systems costed in the model include a motor, blades, and a
steel tank for storage of scraped material for one year. There is also a setup cost and a cost for
cleanout of the existing lagoon (see Section 5.4). When facilities are retrofitted to a scraper
system, the dilution factor is set to 1, no additional water is added, and scraped material is moved
to a covered steel tank to limit dilution by precipitation.
It is assumed that each animal house has a single alley requiring one scraper system
(Figure 5.17.2-1). Each scraper has two blades. Steel scraper blades last for 10 years (MDS,
2002). Since costs are amortized over 20 years, four steel blades are purchased at $177 each as
capital costs. This cost is based upon $29.50 per foot for 6-foot blades (MDS, 2002). EPA
assumes a setup cost of $36,000 per house, and $200 for a 1/4 HP motor. The volume of waste
to be stored in the tank is calculated from the following equation:
where:
VolumeManureUndilutcd = nohead x weight -s-1,000 x volume x 365 x 7.481
ManureUndiluted
Volume;
nohead
weight -5-1000
volume
Annual volume of undiluted manure, gallons/year
Number of head
Animal weight divided by 1,000 = Number of animal
units
Cubic feet of manure produced per animal unit per
day
5-141
-------
365
7.481
Days per year
Gallons per cubic foot.
Scraper Blades
Stalls
17
Alley
Stalls
Figure 5.17.2-1. Scraper System
Capital Costs
Retrofit costs (minus lagoon cleanout costs) are calculated using the following
equation:
Capital Cost = ((Setup + Motor) + (Blades* 177)) x Number + (VolumeManureUndi,uled x Tankcost)
where:
Setup
Motor
Blades
177
Setup cost of $36,000
Motor cost of $200
Number of steel scraper blades (4)
Cost of steel scraper blades
5-142
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Number
Tankcost
Number of retrofit units
Cost of steel tank ($0.18 per gallon).
Annual Costs
Annual operation and maintenance include labor, electricity, replacement blades
and standard maintenance. EPA .estimates motor usage for each unit to be 897 kWh at $0.095
per kWh. Labor for each unit is estimated to be 52 hours per year at $10 per hour, and
maintenance is estimated at 2 percent of initial costs, including cleanout of the lagoon ($724).
Annual costs are calculated using the following equation:
Annual Cost = (Electricity x Rate + Hours x Labor) x Number + Capital Cost x 0.02
where:
Electricity =
Rate =
Hours =
Labor =
Number =
CapitalCost =
0.02
Annual electricity usage per unit
Cost of electricity
Labor per unit
Labor rate
Number of retrofit units
Capital Cost (including lagoon cleanout)
Standard maintenance rate.
5.17.3
Retrofit to High Rise Hog Houses
Menke, et al. (2000) evaluated the construction costs for a two-story confinement
housing design. Material falls through open slots onto the first floor where it is composted with
carbon-rich material. A high-rise house for 1,000 head of finishing pigs is 44 feet * 190 feet. On
a per pig basis, a traditional deep pit house in Indiana/Ohio costs $155 to 160 per animal; a
lagoon style flush house costs $145 per animal; and the high-rise building costs $185 per animal.
The high-rise building costs include professional engineering design that meets NRCS design
standards. Building a deep-pit house to these standards is estimated to increase the construction
cost of a deep-pit house by $15,000 ($15 per animal).
5-143
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Operation and maintenance costs for a high-rise hog facility are estimated at 2
percent of initial costs. Additional costs include energy costs and drying agents. Energy costs for
a traditional confinement building are estimated at $2,500 to $2,800 per year. The high-rise
building has average monthly costs of approximately $400 or $4,800 annually. Drying agents
evaluated include wheat straw, corn stalks, and wood shavings. Around 50 to 60 tons of wood
shavings are needed to cover the house at a depth of 2 feet at an annual cost of $4,000 to $5,000
per year. In contrast, 5 feet of straw or corn stalk material are needed to absorb similar amounts
of moisture. Even at a lower cost of $9 to $10 per 1,200 pound bale of com stalks, the higher
volumes required offset the unit cost savings. Straw and corn materials also tend to degrade and
compost more rapidly than wood, requiring more frequent addition of drying material to the
house. .-'.i :
The cost of feed and manure handling are assumed to be no different from
baseline. Therefore, the initial cost of high-rise buildings for hogs is calculated using the
following equation:
where:
Nohead
Construction
Capital Cost = Nohead x Construction
Number of head
Cost of construction ($185 per pig space).
Annual costs are estimated with the following equation:
where:
Annual Cost = Nohead x Operation + Capital Cost x o .02
Nohead
Operation
Number of head
Cost of confinement fuel, repairs, and utilities ($3.22 per
Pig)-
5-144
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5.17.4
Retrofit to Hoop Houses
Hoop structures are low-cost, Quonset-shaped swine shelters with no form of
artificial climate control. Wooden or concrete sidewalls 4 to 6 feet tall are covered with an
ultraviolet and moisture-resistant, polyethylene fabric tarp supported by 12- to 16-gauge tubular
steel hoops or steel truss arches placed 4 to 6 feet apart. Hoop structures with a diameter greater
than 35 feet generally have trusses rather than the tubing used on narrower hoops. Some
companies market hoops as wide as 75 feet. Tarps are affixed to the hoops using ropes or winches
and nylon straps.
Generally, the majority of the floor area is earthen, with approximately one-third of
the south end of the building concreted and used as a feeding area. Approximately 150 to 200
finisher hogs or up to 60 head of sows are grouped together in one large, deep-bedded pen.
Plentiful amounts of high-quality bedding are applied to the earthen portion of the structure,
creating a bed approximately 12 to 18 inches deep. The heavy bedding absorbs animal manure to
produce a solid waste product. Additional bedding is added continuously throughout the
production cycle. Fresh bedding keeps the bed surface clean and free of pathogens and sustains
aerobic decomposition. Aerobic decomposition within the bedding pack generates heat and
elevates the effective temperature in the unheated hoop structure, improving animal comfort in
winter conditions.
The costing for hoop houses is similar to that for high-rise houses. Capital costs
are estimated using the following equation:
Capital Cost = Nohead x Construction
where:
Nohead =
Construction =
Number of head
Cost of construction ($55 per pig space).
Annual costs are estimated with the following equation:
5-145
-------
where:
Annual Cost = Nohead x (Operation + Bedding + Hours x Labor) + Capital Cost x 0 .02
Nohead
Operation
Bedding
Hours
Labor
Number of head
Cost of confinement fuel, repairs, and utilities ($1.40 per
pig)
Cost of bedding ($4.20 per pig)
Labor (1.12 hours per pig) .
$10 per hour.
5.18
Recycling of Flush Water
In liquid-based systems, fresh water can be used for flushing or water from a
secondary lagoon can be recycled as flush water. This technology is applied to Category 2,
lagoon-based swine operations for all options except Option 5.
Costing for this technology includes piping, labor, and an extra lined lagoon
designed to provide an additional 20 days of storage. The design of the extra lagoon is discussed
hi Section 5.4.5, and lagoon liners are described in Section 5.4.2. EPA assumes that 250 feet of
pipe are required to connect the extra lagoon to the pump, at a cost of $2.13 per foot. It is
estimated that 4 hours of labor is required to install the pipe and set up the pump, at a cost of
$10/hour.
Capital Cost
The capital costs are estimated with the following equation:
Capital Cost = Pipelength x Pipecost + Hours x Labor + ExtraLagoon + Liner
where:
Pipelength =
Pipecost =
Hours =
Labor =
Length of pipe
Cost per foot of pipe
General labor hours to install pipe and pump
$10/hour
5-146
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ExtraLagoon =
Liner =
Cost to build lagoon with storage for 20 days
Cost of liner for extra lagoon.
The cost to build the extra lagoon is estimated by multiplying the lagoon volume
by the earth moving cost of $2.60 per cubic yard. The cost of the liner is determined by
multiplying the surface area of the liner (bottom plus sides) by the liner cost of $1.84 per square
foot (clay plus synthetic).
Annual Costs
The annual cost is calculated with the following equation:
Annual Cost = Capital Cost x 0.02
5.19
Sludge Cleanout
Sludge must be removed from lagoons periodically to keep storage capacity
available. The cost model accounts for sludge cleanout annually for beef feedlots, dairies, and
heifer operations and once every five years for liquid-based swine operations for all considered
options.
5.19.1
Technology Description
Nondegradable solids settle to the bottom of lagoons as sludge, which is
periodically removed. The liquid is applied to on-site cropland as fertilizer or irrigation water, or
it is transported off site. The sludge can also be land applied as a fertilizer and soil amendment.
Compared with lagoon liquids, lagoon sludges have higher concentrations of all
pollutants that are not completely soluble. Some organic N associated with heavier and
nondegradable organics also settles into the lagoon sludge and stays, resulting in a high-organic N
fraction of total Kjeldahl N (TKN) in settled solids.
5-147
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Beef and Dairy Model
For the beef, dairy, and sludge operations, sludge removal is assumed to occur
annually because of the higher capacity requirements associated with liquid storage receiving
runoff from open lots. Cost for removing the sludge is determined using a cost test against three
options: .
1) Lagoon or pond is pumped to a traveling gun. Sludge is applied to land on
site using the traveling gun.
2) Lagoon or pond is pumped to a tanker truck owned and operated by the
operation owner. The tanker truck ships the sludge to an off-site location.
3) A custom applicator brings equipment on site, removes the sludge, and
ships the sludge off site.
Hauling costs incurred by the owner/operator are included in Section 5.9.
5.19.2
Beef and Dairy Costs
Capital Costs
The cost model assumes that facilities with less than 30 acres may choose to
purchase a traveling gun or contract with a custom applicator to remove sludge from their
lagoons. The model assumes that facilities with 30 or greater acres may choose to purchase a
tanker truck to haul their own waste or will contract with a custom applicator to remove sludge
from their lagoons. Costs for a traveling gun are outlined in Section 5.8 and costs to purchase a
tanker truck are outlined in Section 5.9. Contracting with a custom applicator has no assumed
capital costs.
5-148
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Annual Costs
Annual costs for traveling guns and tanker truck hauling are estimated at 5 percent
of the capital costs. Annual costs for contracting with a custom applicator are estimated at $0.05
per gallon of sludge. Appendix Table A-19 presents sludge removal costs for beef feedlots,
dairies, and heifer operations.
5.19.3
Swine Costs
For the swine cost model, zero cost is assumed for sludge cleanout, but hauling
costs are estimated. The volume of sludge to be hauled is determined using the following
equation: . ' •
VolumeSiudgc = VolumeManure x (1-Given) x Solids x 0.924 x HaulPct x (1-mangive)
where:
Volumesludge
VolumeManurc
Given
Solids
0.924
HaulPct
Mangive
Annual volume of sludge to haul, gallons/year
Annual volume of manure produced, gallons/year
Portion of manure given away, decimal fraction
Solids content of manure, decimal fraction
Moisture content of sludge
Portion x>f manure hauled away, decimal fraction
Frequency factor for giving manure away.
EPA assumes that Category 3 swine operations incur no cost to haul sludge under
N-based management since that is the baseline scenario. For all other Category 2 and 3 liquid-
based swine operations, the cost of hauling the sludge is determined using the following equation:
where:
Costs,udl= = (Volumesludgc x LiquidFirst) + (LiquidAdd x Volumesludge x (Transport - 1))
C°StSludge
Volumes,udge =
LiquidFirst =
LiquidAdd =
Annual cost of hauling sludge
Annual volume of sludge to haul, gallons/year
Liquid hauling cost for first mile
Liquid hauling cost beyond first mile
5-149
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Transport
Transport distance for hauling sludge.
The values of LiquidFirst ($0.008/gallon-mile) and LiquidAdd ($0.0013/gallon-
mile) are taken from Table 5.9.2-3, In cases where feeding strategies are employed (see Section
5.21.9), sludge volume is reduced by the factor (1-FSRed) to account for the reduced quantity of
solid waste produced under feeding strategies. The value of FSRed is 0.40. Further, for the Mid-
Atlantic region, the transport distances are changed if feeding strategies are employed. If the
hauling percentage (HaulPct) is less than 20 percent (0.20), the transport distance is set at 5.5
miles, the distance for N-based management at Category 2 facilities (see Table 5.9.2-1).
Otherwise, the transport distance is set to 18 miles in the Mid-Atlantic region for swine facilities
that use feeding strategies to reduce manure-P production.
5.20
Surface Water Monitoring
Option 4 requires animal feeding operations to monitor nearby water bodies for
contaminants.
5.20.1
Practice Description
Surface water monitoring is used to evaluate the nutrient loading of waterways
near animal feeding operations. The primary purpose of this monitoring is to determine the
effectiveness of implemented technologies and practices at preventing contamination of surface
water. Possible sources of excess loading include uncontained runoff and lagoon overflow during
peak storm events.
The best time to monitor the effectiveness of runoff control systems is immediately
following storm events; therefore, sampling events are not scheduled in advance. Animal feeding
operations are costed for sampling water bodies going through or adjacent to feeding operations
immediately following storm events, up to 12 times per year.
5-150
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5.20.2
Prevalence of the Practice in the Industry
It is assumed that beef feedlots, dairies, and veal operations do not have surface
water monitoring programs in place, therefore, the cost model assigns the cost of surface water
monitoring to every operation evaluated under Option 4. Note that Option 4 is the only option in
the cost model that includes surface water monitoring.
5.20.3
Design
The design for surface water monitoring is based on the sampling program and
includes monitoring at the surface impoundment (pond or lagoon) and the stockpile. The
requirements of the sampling program are:
• Twelve sampling events per year at surface water bodies;
• One sampling event per year at the lagoon or pond and at the stockpile;
• Four grab samples and one quality assurance (QA) sample per sampling
event (Table 5.20-1 shows the total number of samples'over a one-year
period);
• Sampling will coincide with rain events in excess of 0.5 inches
precipitation; and
• Analysis of each sample for nutrients (nitrite, nitrate, total Kjeldahl
nitrogen, total phosphorus) and total suspended solids (TSS).
An alternative analysis considered ambient monitoring for metals (zinc, arsenic,
copper), BOD5, and biological organisms (fecal conforms, enterococcus, salmonella, and
escherichia coli). Due to high costs and limited holding times for BOD and pathogen samples,
these parameters were not costed for Option 4. EPA believes the uncertainty of precipitation
events prevents the CAFO owner from being prepared to rapidly sample; therefore, accurate
sample collection and shipping would be very difficult for these additional constituents.
5-151
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r
5.20.4
Table 5.20-1
Number of Samples
1 Number of sampling events per year
Number of samples per sampling event (4 grab + 1 QA)
Total annual samples
12
5
60
Costs
Initial cost estimates, shown in Table 5.20-2, include training, coolers, and
reusable sampling equipment Annual costs, shown in Table 5.20-3, include sterile containers and
sampling supplies for each sampling event, labor costs associated with sampling, sample overnight
shipment, and lab processing fees.
Table 5.20-2
Capital Costs for Surface Water Sampling
Description
Training (8 hr)
Course fee
Misc. other costs (15% of labor)
Coolers (2)
Sampling equipment (pipet, etc.)
Unit Cost
$10/hr
$40
—
$30/cooler
$200
Total Capital Cost
Capital Cost ;
$80
$40
$12
$60
$200
$392
5-152
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Table 5.20-3
Annual Costs for Surface Water Sampling
: Description ,-
250-mL bottles (2 per sample)
500-mL bottles (1 per sample)
Overnight shipping (30-lb cooler)
Misc. supplies and transportation
Laboratory costs
Sample collection (2 hrs/sampling event)
QA & recordkeeping (1 hr/sampling event)
Unit Cost
$2/bottle
$2.70/bottle
$60/sampling event
$30
$79/sample
• $ro/hf
$10/hr . .. .
Annual Cost
$240
$162
$720
$30 ,
$4,740
$240' '
. . : — $120
5.20.5
Results
The cost model results for the surface water monitoring option do not vary
between animal type, region, or size group. The capital cost for surface water monitoring is
$392, and the annual cost is $6,252.
5.21
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5-158
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6.0
FREQUENCY FACTORS
EPA recognizes that most individual farms are currently implementing certain
waste management techniques or practices that are called for in the regulatory options considered.
Only costs that are the direct result of the regulation are included in the cost model. Therefore,
costs already incurred by operations are not attributed to the regulation.
Frequency factors are used in the cost model to simulate a cost allowance by
reducing the expenditures necessary to bring a farm into compliance with the regulatory options
considered. In other words, compliance costs are set to less than 100 percent of the cost of
needed practices if farms are already implementing all or part of these practices or equivalent
practices. The resulting cost could be viewed as an allowance. The degree to which costs are
reduced is directly linked to the extent to which the required practices are already being
implemented.
TO reflect baseline industry conditions, EPA developed technology frequency
factors to describe the percentage of the industry that already implements particular operations,
techniques, or practices that may be used to meet the requirements of the final rule. In some
cases, these frequency factors are based on an assumed performance category (i.e., high, medium,
and low performance) as estimated by U.S. Department of Agriculture (USDA). EPA also
t
developed ground water control frequency factors based on the location of the facility and current
state requirements for permeabilities of waste management storage units. In addition, EPA
developed nutrient basis frequency factors describing the distribution of farms that would apply
manure to soils on a nitrogen or phosphorus basis, land availability frequency factors describing
the distribution of farms with and without sufficient cropland to land apply the manure and
wastewater generated at the farm, and transportation frequency factors describing the distribution
of farms transporting excess manure and wastewater off site.
Some technologies included in the cost model, including composting and anaerobic
digestion, were assumed not to be present under baseline industry conditions. Therefore, EPA
6-1
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assumed all of the facilities incur the cost of implementing the technologies and did not develop
frequency factors for these technologies.
This section presents the frequency factors and the methodologies used to develop
them in the following subsections:
Section 6.1- Beef and Dairy Technology Frequency Factors;
Section 6.2 - Beef and Dairy Nutrient Basis Frequency Factors;
Section 6.3 - Beef and Dairy Land Availability Frequency Factors;
Section 6.4 - Swine and Poultry Technology Frequency Factors;
Section 6.5 - Swine and Poultry Nutrient Basis Frequency Factors;
Section 6.6 - Swine and Poultry Land Availability Frequency Factors; and
Section 6.7 - Ground Water Control Frequency Factors.
6.1
Beef and Dairy Technology Frequency Factors
Technology frequency factors reflect the percentage of operations that have a
particular operation, technique, or practice (e.g., settling basin) in place at baseline (i.e., prior to
implementation of the regulation). Frequency factors are based on geographic location, type and
size of operation, existing regulatory requirements, and overall status of the industry. EPA
developed technology frequency factors for practices or technologies included in the cost model,
including:
• Solids separation using earthen settling basins;
• Runoff controls (i.e., berms);
• Liquid land application (e.g., center pivot irrigation);
• Nutrient management planning (i.e., setbacks, lagoon markers, soil
sampling, manure sampling, recordkeeping, document preparation);
• Solids separation using concrete settling basins;
• Naturally lined ponds and lagoons; and
• Transportation.
6-2
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: Frequency factors were developed to represent the current implementation rate of
various practices used on operations. Since current implementation can vary significantly across
operations in a given sector, the frequency factors were developed to represent low, medium, and
high implementation costs based on farm performance. For example, operations classified as "low
implementation cost" generally tend to have already implemented the practice and thus "low" (or
no) additional costs are expected for such operations. Conversely, "high implementation cost"
operations are assumed to have little or low levels of implementation and are expected to have
"high" additional costs to implement a given practice or meet a certain standard. EPA assumed
that 50 percent of all facilities would incur "medium", costs, 25 percent of facilities would incur
"low" costs, and 25 percent would incur "high" costs.
EPA developed technology frequency factors that vary by farm performance using
the same methodology and source of USD A data. Section 6.1.1 discusses the development of
these frequency factors for beef feedlots, dairies, heifer operations, and veal operations.
Frequency factors for some technologies were not included in USDA's data. The development of
factors that were not presented in the USDA data that were assumed to vary by level of
performance is described in Section 6.1.2 for beef feedlots, dairies, heifer operations, and veal
operations. The remaining technology frequency factors are not assumed to vary by farm.
performance. EPA developed these remaining technology frequency factors using several different
data sources. Section 6.1.3 discusses these frequency factors for beef feedlots, dairies, heifer
operations, and veal operations. Section 6.1.4 discusses the frequency factors developed for the
swine and poultry cost model.
6.1.1
Performance-Based Frequency Factors Based on USDA Data
EPA received frequency factors from USDA as part of a document entitled
Estimation-of Private and Public Costs Associated with Comprehensive Nutrient Management
Plan Implementation: A Documentation (April 23, 2001). This document includes frequency
factors for three performance-based categories of facilities (low-performing, medium-performing,
and high-performing) for a series of "representative" farms defined by USDA in eight USDA
6-3
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defined regions. USD A defined high performers to be 25 percent of the facilities, medium
performers to be 50 percent of the facilities, and low performers to be 25 percent of the facilities.
EPA also used these percentages to calculate the number of facilities that are high, medium., and
low performers.
To use USDA's frequency factors in the cost models, EPA "mapped" USDA's
representative farms to its model farms and then weighted the frequency factors by the percent
distribution of farms within each region. The general methodology used to perform this
translation is provided below. See ERG's memorandum to the record Methodology to
Incorporate USDA Frequency Factors into Beef and Dairy Cost Model Methodology (ERG,
2001) for a more detailed description of the methodology and USDA data used for beef feedlots,
dairies, and heifer and veal operations.
Mapping USDA Representative Farms to EPA Model Farms
To use these performance-based frequency factors for beef feedlots, heifer
operations, dairies, and veal operations, EPA correlated the USDA representative farms and
regions to EPA's model farms and five geographic regions. To do this, EPA divided each USDA
region into individual states and then weight-averaged the frequency factors from each state in
that region to calculate the frequency factors for that region, according to the total number of
operations in each state.
EPA's cost methodology for beef feedlots and heifer operations uses a single
model farm to represent the costs of the majority of beef feedlots and heifer operations in the
country with greater than 300 head. USDA's frequency factors for beef are based on two
representative farms in eight geographic regions. The USDA factors are presented for the
following size groups:
>30;
>100;
30 - 500;
>500;
6-4
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30-1,000; and
>1,000 head.
EPA correlated these size groups to the Agency's size groups of 300 - 499 (Medium 1), 500 -
999 (Medium 2 and 3), and > 1,000 (Large 1) head. EPA applied USDA's assumptions for beef
feedlots to heifer operations since USDA's data did not include information for heifer operations.
EPA's cost methodology for dairies uses two model farms to represent the costs of
the majority of dairies in the country with greater than 200 head. The USD A methodology uses
five representative farms to reflect the current state of the industry. No "dairies with greater than
200 head'are represented by USDA's farm #1 and only a small portion are represented by
USDA's farm #2. Therefore, EPA used frequency factors from only USDA farms #3, #4, and #5.
The Agency did not compare veal operations because EPA assumes that all veal
operations currently have" appropriate waste management practices in place and would require
nutrient management planning.
Tables 6.1.1-1 and 6.1.1-2 present the correlation of EPA model farm components
to the USDA representative farm components for beef feedlots and dairies, respectively.
Weighting USDA Frequency Factors
To use USDA's frequency factors at EPA model farms, EPA first weighted the
frequency factors by the percent distribution of farms in a given USDA region. For example, if a
USDA region was described using representative farm #1 and representative farm #2, and the
USDA weighting factors indicate that 30 percent of operations in this region are represented by
farm #1 and 70 percent of operations are represented by farm #2, then the weighted frequency
factor for that region is:
Weighted frequency factor'= Frequency factor FannS1 x 0.3 + Frequency factor Faml#2 * 0.7
6-5
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Next, EPA determined the states included in the USDA regions and estimated how
many USDA facilities were in each state. EPA then calculated the percentage of the total number
of EPA facilities in each USDA region using its estimates of the number of facilities in each state.
These percentages provide the basis for weighting the USDA frequency factors to create the
frequency factor for the EPA region. Table 6.1.1-3 presents the portion of beef feedlots and
heifer operations and Table 6.1.1-4 presents the portion of dairies from the USDA region that fall
within the corresponding EPA region, expressed as a percentage of the total EPA beef feedlots,
heifer operations, and dairies in that region.
Table 6.1.1-1 "
Correlation of EPA Beef Model Farm Components and USDA Representative
Farm Components
Animal Type
Beef
EPA Model Farm
Partially paved drylot
Concrete pad
(Options 3 & 4)
Berms
Stormwater pond
Earthen settling basin
Solids land application
Liquid land application
Nutrient management
planning
Off-site transportation
•\,^--^^.-:^.^
Lot with smooth, hardened
surface
Concrete slab for manure
Adequate clean water
diversion system
Adequate runoff storage pond
Not listed
Appropriate solids collection/
spreading/transfer equipment
Appropriate liquid collection/
spreading/transfer equipment
Manure and soil testing
One-time documentation of
facility
Routine recordkeeping
Off-farm export
ntatiye Farm* . : ,:;
^XV^v-;'- .
Graded, curbed, fenced, lots
Not listed
Adequate clean water
diversion system
Adequate runoff storage pond
Adequate settling basin
Appropriate solids collection/
spreading/transfer equipment
Appropriate liquid collection/
spreading/transfer equipment
Manure and soil testing
One-time documentation of
facility
Routine recordkeeping
Off-farm export
This list includes all components included for that representative farm in all regions.
6-6
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Table 6.1.1-2
Correlation of EPA Dairy Model Farm Components and USDA
Representative Farm Components
Animal Type
Dairy
EPA. Model Farm
Berms
Concrete settling
basin
Anaerobic lagoon
Liquid land
application
Nutrient
management
planning
Off-site
transportation
USDA Representative Farm"
#3 - ,
Adequate clean
water diversion
system
Separator or settling.
basinb
Adequate liquid
storage
Appropriate liquid
spreading/transfer
equipment
Manure and soil
testing
One-time
documentation of
facility
Routine
recordkeeping
Off-farm export
" #4 "
Adequate clean
water diversion
system
Separator or settling
basinb
Adequate liquid
storage
Appropriate liquid
spreading/transfer
equipment
Manure and soil
testing
One-time . . . . .
documentation of
facility
Routine
recordkeeping
Off-farm export
#5
Adequate clean
water diversion
system
Separator or settling
basinb
Adequate liquid
storage
Appropriate liquid
spreading/transfer
equipment
Manure and soil
testing
One-time
documentation of
facility
Routine
recordkeeping
Off-farm export
"This list includes all components included for that representative farm in all regions.
bA footnote on the USDA tables indicates that 30 percent of operations have a separator or settling basins.
6-7
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Using the percentages in Tables 6.1.1-3 and 6.1.1-4, EPA calculated the weighted
frequency factors for each of the five EPA regions. For example, for beef feedlots in the EPA
Central region, a frequency factor can be calculated using the following formulas:
USDA Region A Frequency Factor x 0.10 = USDA portion A
USDA Region B Frequency Factor x 0.19 = USDA portion B
USDA Region C Frequency Factor x 0.15 = USDA portion C
USDA Region D Frequency Factor x 0.56 = USDA portion D
Sum of USDA portions = EPA regional frequency factor
Table 6.1.1-3
Percentage of EPA Beef Feedlots and Heifer Operations in USDA Regions
Animal Type
Beef
Heifer
EPA Region
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South
USDA Regions"
"A
0.10
0
0.13
0
0
0.02
0
0.27
0
0
-B
0.19
0
0
1
0
0.48
0
0
1
0
C
0.15. ;
0
0.16
0
0
0.13
0
0.15
0
0
D
. 0.56, ,
0
0
0
0
0.38
0
0
0
0
•E
0;,
0.05
0
0
0
0
0
0
0
0
F
0
0
0.70
0
0
0
0
0.54
0
0
G
0
0.45
0
0
0
0
0
0
0
0
H
0
0.50
0
0
1
0
0
0
0
0
"Region A: MT,WY,ND,MN
Region B: CA, AZ, AK, HI, UT, NV, WA, OR, ID
Region C: CO.KS.NE.SD
Region D: TX.OK.NM
Region E: MA, RI, CN, VT, NH, ME
Region F: MO, IL, IN, OH, MI, WI, IA
Region G: PA,NY,NJ
Region H: VA, WV, MD, DE, NC, TN, KY, SC, GA, AL,
MS, FL, AR, LA
6-8
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Table 6.1.1-4
Percentage of EPA Dairies in USDA Regions
• -Animal Type :
Dairy
EPA Region
Central
Mid-Atlantic
Midwest
Pacific
South
USDA Regions"
Dairy Belt
0
0.74
1 ..,--
. ... o ...
0
Southeast
0
0.26
0
0
1
West
1
0
0
1
0
"Dairy Belt Region - MN, IA, MO, WI, IL, MI, IN, OH, PA, NY, VT, ND, SD, ME, KS, NJ, MD, DE, MA, Ct, RI, NH, ME
Southeast Region - KY, TN, PL, VA, WV, NC, SC, GA, AL, MS, AR, LA .. ._.,..
West Region - CA, OR, WA, ID, NM, TX, HI, AK, AZ, UT, NV, MX, WY, CO, OK .
Frequency Factors for Earthen Settling Basins
-•tt-'.-..
All regulatory options assume that beef feedlots and heifer operations require an
earthen basin to collect runoff. The regulatory options also assumed that dairies and veal
operations have concrete basins instead of earthen basins due to the higher flow of water from the
barn and parlor cleaning operations that enter the settling basin. Table 6.1.1-5 lists the percentage
of beef feedlots and heifer operations that would incur costs for earthen basins by size class,
region, and requirements.
Frequency Factors for Runoff Controls
Under all regulatory options, CAFOs are required to contain any runoff collecting
in potentially contaminated areas. For the purpose of estimating compliance costs, EPA assumes
that facilities will use berms to control runoff. Table 6.1.1-6 presents estimates of beef feedlots,
heifer operations, and dairies that will incur costs to install berms based on size class, -~
requirements, and regional location. EPA assumes that veal, swine, and poultry operations do not
require berms.
6-9
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Table 6.1.1-5
Percentage of Beef Feedlots and Heifer Operations Incurring Earthen
Basin Costs for All Regulatory Options
Animal
Type
Beef
and
Heifers
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2'
Performance
High
Medium
Low
High
Medium
Low
. . . •;,•. . - . ••Region.;. -;;.:. ,., . -s,-r.r
Central
100%
80%
40%
100%
80%
40%
Mid-Atlantic
100%
80%
40%
100%
80%
40%
Midwest !
100%
80%
40%
100%
- . 80%
40%
•• Pacific
100%
80%
40%
100%
80%
40%
South
100%
80%
40%
100%
80%
40%
•Large 2 size class represents only beef feedlots.
Frequency Factors for Liquid Land Application
Under all regulatory options, beef feedlots, heifer operations, and dairies are
assumed to land apply their liquid manure and process wastewaters. Table 6.1.1-7 presents
estimates of beef feedlot, heifer operations, and dairies that will incur costs (i.e, purchase liquid
land application equipment) to apply liquid manure and wastewaters to .their cropland based on
size class, requirements, and regional location. EPA assumes that all veal operations have
appropriate equipment for liquid land application and, therefore, do not incur any additional costs.
Frequency Factors for Nutrient Management Planning
Under all regulatory options, beef feedlots, heifer operations, and dairies are
assumed to incur costs associated with nutrient management planning. Nutrient management
planning includes setbacks, lagoon depth markers, soil sampling, manure sampling, recordkeeping,
and document preparation. Table 6.1.1-8 presents estimates of beef feedlots, heifer operations,
and dairies that will incur costs to comply with the nutrient management planning requirements
based on size class, requirements, and regional location. All veal operations (100 percent) are
assumed to incur costs for nutrient management planning.
6-10
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Table 6.1.1-6
Beef Feedlots, Heifer Operations, and Dairies Incurring Costs to Install and
Maintain Berms for All Regulatory Options
Animal Type
Beef and
Heifers
Dairy
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2"
Medium 1
Medium 2
Medium 3
Large 1
Performance
High
Medium
Low
High
Medium
Low
•• High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
Region
Central
74%
56%
32%
71%
54%
'.29%
74%
56%
32%
67%
51%
23%
50%
40%
0%
30%
10%
0%
30%
10%
0%
30%
10%
0%
30%
10%
0%
Mid-
Atlantic
92%
32%
21%
92%
32%
21%
92%
32%
21%
92%
32%
21%
92%
32%
21%
34%
21%
7%
34%
21%
7%
34% ,
21%
7%
33%
20%
8%
Midwest
59%
46%
12%
55%
43%
6%
59%
46%
12%
50%
40%
0%
50%
40%
0%
59%
36%
14%
59%
36%
14%
59%
36%
14%
' 58%
38%
18%
Pacific
50%
40% ,
0%
50%
40%
0%
50%
40%
0%
50%
40%
0%
50%
40%
0%
30%
10%
0%
' 30%
10%
0%
30%
10%
0%
30%
10%
0%
South
85%
65%
43%
84%
65%
43%
85%
65%
43%
85%
65%
43%
85%
65%
43%
40%
20%
0%
40%
20%
0%
40%
20%
0%
40%
20%
0%
"Large 2 size class represents only beef feedlots.
6-11
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Table 6.1.1-7
Beef Feedlots, Heifer Operations, and Dairies Incurring Costs for Liquid Land
Application for All Regulatory Options
Animal
Type
Beef and
Heifers
Dairy - Flush
Dairy - Hose
Size Class
Medium 1
Medium 2
Mediums
Large 1
Large 2"
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Large 1
Requirements
High
Medium
Low
High_
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
High
Medium
Low
Central
100%
,70%
32%
100%
70%
33%
100%
70% .
32%
100%
70%
34%
100%
70%
40%
50%
30%
10%
50%
30%
10%
50%
30%
10%
Mid-
Atlantic
.80% _-,
56%
26%
,80%
56%
26%
80%
56%
26%
80%
56%
26%
80%
56%
26%
55%
40%
21%
57%
39%
19%
55%
40%
21%
Region
Midwest
,100%
70%
37%
100%
70%
38%
100%
70%
37%
100%
70%
40%
100%
70%
40%
92%
57%
14%
91%
55%
13%
92%
57%
14%
"Pacific
100%
,70% ,
40%
100%
70%
40%
100%
70%
40%
100%
70%
40%
100%
70%
40%
50%
30%
10%
50%
30%
10%
50%
30%
io%-
South
. 97%
67%
24%
.. 97% __
67%
24%
97%
67%
24%
97%
67%
24%
97%
67%
24%
65%
51%
37%
65%
51%
37%
65%
51%
37%
'Large 2 size class represents only beef feedlots.
6-12
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Table 6.1.1-8
Beef Feedlots, Heifer Operations, and Dairies Incurring Costs for Nutrient
Management Planning for All Regulatory Options
Animal
Type
Beef and
Heifers
Dairy - Flush
Dairy -
Scrape
Size Class
Medium 1
Medium 2
Medium 3
. Large 1
Large 2a •
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Requirements
High
Medium
Low
.High
Medium
. Low
High •
Medium
Low
High
Medium
Low
High
Medium
- Low
i * " ¥ ~ Region
Central
100%
90%
80%
100%
90%
80%
100%
90%
80%
100%
90%
80%
100%
90%
80%
Mid-
Atlantic :
100%
95%
79%
100%
95%
79%
63%
57%
50%
64%
58%
51%
63%
57% .
50%
Midwest
100%
90%
80%
100% .
90%
80%
100%
90%
80%
100%
90%
80%
100%
90%
80%
Pacific
100%
90%
80%
100% .....
90%
80%
100%
90%
80%
100%
90%
80%
100%
90%
80%
South
100%
93%
80%
100%
93%
80%
100%
90%
80%
100%
90%
80%
100%
90%
80%
"Large 2 size class represents only beef feedlots.
6-13
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6.1.2
Other Performance-Based Frequency Factors
For some technologies, USD A did not provide data based on farm performance.
Therefore, EPA used implementation rates identified in literature, which are provided as single
values rather than a range of values. Because EPA believes that the implementation of these
technologies varies according to farm performance, EPA used the single values to calculate the
range of frequency factors for these technologies using the following methodology:
1)
2)
Identify the overall frequency of implementation of the .technology or practice
Let X = the overall implementation, or frequency factor.
If X 25%, then
Low Frequency factor,
Medium Frequency Factor
Highest Frequency Factor
If 25%<75%,then
Low Frequency factor
Medium Frequency Factor
Highest Frequency Factor
If X ;>75%, then
Low Frequency factor
Medium Frequency Factor
Highest Frequency Factor
0% .
0%
"X -25%
PC r 25%)*. 50%
100%
PC- 75%) -s-25%
100%
100%
Thus, it was assumed that low implementation cost operations had a frequency
factor of 100 percent (100 percent of facilities had implemented the practice) and high
implementation cost operations had a frequency factor of 0 percent. "Medium implementation
cost" was then calculated by assuming that 25 percent of the operations incurred low
implementation cost, 25 percent incurred high implementation cost, arid the remaining 50 percent
incurred medium implementation cost. For example, if literature reported the actual
implementation rate to be 65 percent, the low and high implementation cost frequency factors
were assumed to be 100 and 0 percent, respectively. The medium implementation cost frequency
factor would be computed as 80 percent.
6-14
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The frequency factors for concrete settling basins in the beef and dairy cost model was calculated
in this way, as shown in Table 6.1.2-1.
Table 6.1.2-1
Frequency Factors Identified from Literature and Used to Calculate Low,
Medium, and High Frequency Factors for Beef and Dairy Cost Model
Technology or
Practice
Concrete Settling
Basin
Size Class
Medium
Large
Overall Frequency
Factor
20%
r •••~33%""1' -
Implementation Cost Frequency Factor
Low' t
0%
0% -v"
Medium
~ ""0%
• 16%-:
High -
80%
100%
6.1.3
Other Technology Frequency Factors
Some of the technology components ofEPA's cost models are not based on
USDA-'s performance-based data. Frequency factors for naturally lined ponds, lagoons, and
transportation costs are based on several different data sources and are described below.
Naturally Lined Pond and Lagoon Frequency Factors
The cost models for beef feedlots, heifer operation, dairies, veal operations, swine
operations, and wet layer operations include naturally lined ponds and lagoons. This subsection
presents the frequency factors for beef feedlot, dairies, heifer and veal operations.
Using information from site visits and state and federal regulations, EPA assumed
that all large-sized beef feedlots and all large dairies have adequate storage for process
wastewater consistent with the 1974 regulation. EPA developed frequency factors for medium-
sized beef feedlots with naturally lined ponds using site visit information and best professional
judgment. Based on discussions with the Professional Dairy Heifer Growers Association, EPA
6-15
-------
assumed that heifer operations operate like beef feedlots; therefore, the Agency used the same
frequency factors for naturally lined ponds for both types of operations.
^ j i .j ^ » •
Frequency factors for medium-sized dairies with naturally lined ponds are based on
site visit information, NAHMS data, and current state and federal regulations. According to
NAHMS, 13.5 percent of dairies in the 500-to-699-head group and 4.3 percent hi the greater than
700 head group do not have any kind- of waste-storage facility. Of the sites visited by EPA, only
one dairy had neither a lagoon nor large storage-tank. Therefore, EPA assumes that the larger the
dairy, the more likely it is to have a lagoon or other waste storage facility. According to ~
NAHMS, dairies of 200 head and-above in the East and Midwest (31:4 and 16.9'percent, ~ "
respectively) are less likely to have lagoons or storage than dairies hi the West (7.9 percent)":
EPA assumes that the smaller dairies (less than 700 mature dairy cows) comprise the largest
percentage of dairies without waste "storage hi each region.
Based on site visits and discussions with the American Veal Association, EPA
assumes that all veal operations have sufficient lagoon capacity to manage all of the manure and
wastewater generated. Table 6.1.3-1 presents the percentage of beef feedlots, heifer operations,
dairies, and veal operations that would incur costs to install a naturally lined pond or lagoon under
Options 1,2,4, 5A, and 6. The percentages do not vary by region. EPA also used these
frequency factors to determine the percentage of facilities requiring additional storage capacity
under Option 7.
Transportation Frequency Factors
EPA developed frequency factors for facilities requiring the off-site transportation
of excess manure and waste for all animal types using hiformation from existing state regulations
(ERG, 2000; EPA, 1999). Frequency factors were developed only for Category 2 facilities
because the percentage of Category 1 and 3 facilities transporting excess manure and waste
remains the same under all regulatory options. EPA assumes that facilities required by their states
to land apply at agronomic rates are using nitrogen-based application rates and already incur the
cost of transporting excess manure and waste off site. EPA assumes that no facilities are
6-16
-------
currently meeting phosphorus-based agronomic application of manure and, therefore, assumes
that all operations costed for phosphorus-based application will incur costs to transport excess
manure. ....
:-"".,.=
Table 6.1.3-1
Percentage of Beef Feedlots, Heifer Operations, Dairies, and Veal Operations
Incurring Costs to Install a Naturally Lined Pond or Lagoon
; •/-' ?-;AiimaCTyp0'";tHS'
Beef and Heifers
Dairy
Veal
M;;Mlip^-jd^s^j|,j:'l;
Medium 1
Medium 2
Medium 3
Large 1 j_' •
-Large 2a
Medium 1
Medium 2
Medium 3
Large 1
All
J^^tiHti^e^l^iU^e^^
' 50%
50% :"
' 50%
0% -•;•-
0%
10% :
10%
10%
0%
0%
"Large 2 size class represents only beef feedlots.
To calculate the frequency factors for Category 2 beef feedlots and dairies, EPA
determined the threshold requirements for nitrogen-based agronomic application of manure for 22
major dairy and beef-producing states based on state regulations. The Agency then used industry
profile and Census of Agriculture data to determine the number of facilities in each state above
both the state threshold and EPA's proposed threshold. EPA recorded the number of facilities
above both thresholds by region; these facilities are assumed to already Incur transportation costs
for excess manure. EPA compared the number of facilities assumed to incur transportation costs
with the number of facilities above the proposed threshold to arrive at regional frequency factors
representing transportation costs. States other than the 22 included in the analysis were assumed
not to require nitrogen-based agronomic application of animal wastes. EPA assumes that heifer
6-17
-------
operations operate the same as beef feedlots and, therefore, heifer operations use the same
frequency factors as beef feedlots. EPA assumes that all veal operations are Category 1
operations and therefore, did not develop transportation frequency factors for these operations.
Table 6.1.3-2 presents the percentage of Category 2 beef feedlots, heifer operations, and dairies
incurring costs for transporting excess manure and waste off site.
' Table 6.1.3-2 __
Percentage of Category 2 Beef Feedlots, Heifer Operations", and "Dairies
Incurring Costs for Transporting Excess Manure and Waste Off Site
Animal Type
Beef
Heifer
Daiiy
- SizeCIass
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
MediumS
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Region __ „
Central
100%
13%
100%
13%
100%
46%
Mid-
Atlantic
100%
6%
100%
6%
100%
34%
Midwest
78%
33%
82%
33%
82%
77%
Pacific
100%
100%
,100%
100%
100%
100%
I
South
100%
100%
100%
100%
100%
54%
6.2
Beef and Dairy Nutrient Basis Frequency Factors
Several cost modules compute component costs separately for both nitrogen- and
phosphorus-based application and are adjusted based on frequency factors that indicate the use of
the component in the industry. For Options 1 and 1 A, the cost model estimates costs for all
operations for nitrogen-based application, and for Option 2A, estimates costs for all operations
for phosphorus-based application. However, under the remaining options, EPA used the soil test
map from USDA's Agricultural Phosphorus and Eutrophication book (USDA ARS, 1999) to
6-18
-------
determine the percentage of facilities in each state that would require nitrogen-based versus
phosphorus-based application rates. The soil map identified the percentage of soil samples in each
state that had soil test P (phosphorus) levels in the "high"or above" categories. States colored red
on the map reported high or above soil test P levels in more than 50 percent of the samples.
Phosphorus levels of greater than 50 parts per million are generally considered "high." States
colored pink/orange reported high or above soil test P levels in 25 to 50 percent of the samples,
and states colored green reported high or above soil test P levels in less than 25.percent of the
samples. , . - ^
Using these results for soil test P levels, EPA made the following assumptions:
Facilities located in "green" states would require only nitrogen-based
applications;
Facilities located in "pink/orange" states would require 40 percent
phosphorus-based and 60 percent nitrogen-based applications; and
Facilities located in "red" states would require 60 percent phosphorus-
based and 40 percent nitrogen-based applications.
EPA adopted this 40/60 and 60/40 split of applications to account for areas within a given state
that would have soils with low phosphorus levels.
Using these determinations, EPA calculated the percentage of operations that
would require phosphorus-based applications under Options 2 through 7 for each region. These
percentages were calculated by animal type, size class, and regions using the following equation:
PFacso/0=
where:
fStateFacR
\ Total Fac
P Facs%
State FacR =
State FacO =
Total Fac =
6()0/o
State FacO
Total Fac
[6-2]
Percentage of facilities, by region, that would require
phosphorus-based application
Number of facilities in a red state
Number of facilities in an orange/pink state
Total number of facilities in that size class and region
6-19
-------
%Pbased
Percentage of facilities that would require phosphorus-based
application for that given state.
EPA calculated the percentage of nitrogen-based application facilities in each
region and size class using the following equation:
N Facs =. 100% - P Facs
[6-3]
where:
N Facs = Percentage of facilities that would require nitrogen-based
application ,,..., ill. „„„:„,:
P Facs = Percentage of facilities that would require phosphorus-based
application.
Table 6.2-1 presents the percentages of nitrogen-based and phosphorus-based
facilities by animal type, by size class, and by region for Options 2 through 7.
6.3
Beef and Dairy Land Availability Frequency Factors
All operations fall into one of three land availability categories depending on the
amount of on-site cropland available for manure application:
Category 1 operations have sufficient land to land apply all of their
generated manure and wastewater at appropriate agronomic rates. No
manure is transported off site.
Category 2 operations do not have sufficient land to land apply all of their
generated manure and wastewater at appropriate agronomic rates. The
excess manure after agronomic application is transported off site.
Category 3 operations do not have any available land for manure
application. All generated manure and wastewater is transported off site.
Facility counts for swine and broiler operations were provided by USDA NRCS
including land availability category; therefore, these model farms did not require disaggregation
using the land availability frequency factors. However, facility counts for layers, pullets, turkeys,
6-20
-------
and cattle operations were not provided by land" availability category!! Therefore^ EPA applied the
land availability categories to the facility counts for these operations.^
Table 6.2-1 '^,L •~_i-i, "
Percentage of Nitrogen-Based and Phosphorus-Based Application Facilities
Animal
Type
Beef and
Heifers
Dairy
Veal
Size CJass
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Application
Percentage Basis
Nitrogen
Phosphorus-. ,^
Nitrogen
Phosphorus
Nitrogen -
Phosphorus
Nitrogen
Phosphorus
Nitrogen -
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
Nitrogen
Phosphorus
' - * ,Re8*on
Central
53%
47% -^
54%
46%
48%
52% •
45%
55%
46%
54%
46%
54%
47%
53%
49%
51%
56%
44%
40%
60%
40%
60%
40%
60%
Mid-
Atlantic
~~51%~
.49% .
51%
49%
49%
. 51%
49%
51%
60%
40%
47%
53%
46% '
54%
44%
56%
44%
56%
60%
40%
0%
0%
0%
0%
Midwest
•- -60%!^"
•" 40%
60%
40%
60% -
- 40%
61%
39%
61%
39%
47%
53'%
47%
53%
49%
51%
50%.
50%
44%
56%
44%
56%
44%
56%
Pacific
40%
60%
,40%
60%
40%
60%
40%
60%
' 40%
60%
40%
60%
40%
60%
40%
60%
40%
60%
0%
0%
0%
0%
0%
0%
South
49%
51%
55%
45%
50%
50%
0%
0%
0%
0%
56%
44%
57%
43%
48%"
52%
47%
53%
0%
0%
0%
0%
0%
0%
6-21
-------
EPA calculated the percentage of facilities in each of these categories using USDA
data. USDA conducted a national analysis of the 1997 Census of Agriculture data to estimate the
manure production at livestock facilities (Kellogg, R, et al, 2000). As part of this analysis, USDA
estimated the number of confined livestock facilities that produce more,manure than they can
land-apply on their available cropland and pasturelands at agronomic rates for nitrogen and
phosphorus and the number of confined livestock operations that do not have any available
cropland orpastureland. This analysis also identified the amount of excess manure at the facilities
with insufficient land.
EPA used USDA's facility counts to develop the percentage of facilities that are
classified as Category 2 and 3 under a 100-percent nitrogen-based application scenario and a 100-
percent phosphorus-based application scenario. EPA estimated the percentage of facilities
classified as Category 2 and 3 using the following equations:
Percent Category 2 Facs =
No. Farms with Excess Manure (N or P) and Cropland
Total No. Confined Livestock Farms
[6-4]
Percent Category 3 Facs =
No. Farms with Excess Manure (N or P) and No Cropland
Total No. of Confined Livestock Farms
where:
Percent Category 2 Facs
Percent Category 3 Facs
No. Farms with Excess
Manure (N or P) and
Cropland
No. Farms with Excess
Manure (N or P) and
No Cropland
Total No. of Confined
Livestock Farms
[6-5]
Percentage of facilities classified as
Category 2
Percentage of facilities classified as
Category 3
Number of facilities with excess
manure on a nitrogen or phosphorus basis
and some cropland for land application
Number of facilities with excess
manure on a nitrogen or phosphorus basis
and no cropland for land application
Total number of confined livestock farms
EPA estimated the percentage of facilities classified as Category 1 using the following equation:
6-22
-------
Percent Category .l.Facs = 100% - Percent Category 2 - Percent Category 3
[6-5]
where:
Percent Category 1 Facs
Percent Category 2
Percent Category 3
Percentage of facilities classified as
Category 1
Percentage of facilities classified as
Category 2
Percentage of facilities classified as
Category 3
Option 1 uses only nitrogen-based application factors, while Options 2 through 7
use a combination of both nitrogen- and phosphorus-based factors. Table 6.3-1 .presents EPA's
estimated percentage of Category 1, 2, and 3 facilities using nitrogen- and phosphorus-based
applications. ., ...
Table 6.3-1
Percentage of Category 1,2, and 3 Facilities Using Nitrogen- and
Phosphorus-Based Applications
Animal
Type
Beef
Dairy
Heifer
Veal
Size
Class
Medium 1
Medium. 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3.
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Nitrogen-Based Application -'-v
Category 1
84%
68%
8%
50%
27%
84%
68%
100%
Category 2
9%
21%
53%
36%
51%
9%
21%
0%
Category 3
7%
11%
39%
14%
22%
7%
11%
0%
Phosphorus-Based Application
Category;!
62%
22%
1%
25%
10%
62%
22%
100%
^Category!
31%
67%
60%
61%
68%
31%
67%
0%
Category 3
7%
11%
39%
14%
22%
7%
11%
0%
6-23
-------
6.4
Poultry and Swine Technology Frequency Factors
Frequency factors were developed to represent the current implementation rate of
various practices used on operations. Since current implementation can vary significantly across
operations in a given sector, the frequency factors were developed to represent low, medium, and
high implementation costs. For example, operations classified as "low implementation cost"
generally tend to have already implemented the practice and thus "low" (or no) additional costs
are expected for such operations. Conversely, "high implementation cost" operations are
assumed to have little or low levels of implementation and are expected to have "high" additional
costs to implement a given practice or meet a certain standard. Data received from USDA were
presented in this manner for some technologies and practices, including manure testing, soil
testing, record keeping, mortality composting, and adequate mortality storage (Kellogg, 2002).
In some cases, implementation rates in the literature are provided as single values
rather than a range of values. Thus, it was assumed that low implementation cost operations had
a frequency factor of 100 percent (100 percent of facilities had implemented the practice) and high
implementation cost operations had a frequency factor of 0 percent. "Medium implementation
cost" was then calculated by assuming that 25 percent of the operations incurred low
implementation cost, 25 percent incurred high implementation cost, and the remaining 50 percent
incurred medium implementation cost. For example, if literature reported the actual
implementation rate to be 65 percent, the low and high implementation cost frequency factors
were assumed to be 100 and 0 percent, respectively. The medium implementation cost frequency
factor would be computed as 80 percent. In those cases where the medium implementation factor
calculation produced results that were not possible, the low or high frequency factor would be
adjusted down or up, as appropriate, until a realistic medium frequency factor resulted. For
example, if the literature-reported implementation rate was 80 percent, the low and medium
frequency factors would be 100 percent and the high frequency factor would be adjusted up to 20
percent (rather than 0 percent).
6-24
-------
Where data from USDA were not available, EPA .used frequency factors obtained
from other sources, which varied by sector, component, or practice. Industry and USD A data
were used as the basis for most of .the frequency factors for layers and swine; analysis of state and
federal regulations was used primarily for broilers and turkeys. EPA's report on state regulatory
programs (USEPA, 1999) was also used for all animal sectors. Costs were not attributed to
CAFO model farms when state regulations specify standards or require practices equal to or more
stringent than the proposed technology options.
Because the literature and industry provided data for the broiler and turkey sectors
were generally not detailed enough to generate frequency factors, EPA reviewed the specific
regulatory language and summaries of regulations for 12 major poultry-producing states regarding
requirements for nutrient management plans (NMPs) at broiler and turkey farms (Tetra Tech,
2000). Requirements were considered for farms in two size groups: 300 to 1,000 animal units
(AU) and greater than 1,000 AU. All broiler and turkey farms were assumed to use^dry waste
management systems.
From the analysis of state and federal regulations, EPA determined that a few
states already require broiler and turkey farms to implement some of the components of an NMP.
Except as specified for groundwater and surface water requirements, and in cases where select
frequency factors could be based on available industry data, the analysis from these 12 states was
used to calculate regional frequency factors. These regional frequency factors approximate the
number of farms that are currently required to implement NMP components and therefore already
incur costs for these components.
Weighted averages were used to estimate frequency factors for each NMP
component (for 300 to 1,000 AU and >1,000 AU), as illustrated in the example in Table 6.4-1.
The weight reflects the percentage of operations in the entire region already incurring the costs of
that component.
6-25
-------
Table 6.4-1
Illustration of Method to Calculate Frequency Factors from Weighted
Averages
State
A
B
C
D
Number of Farms"
10
40
20
20
100
Component Required?"
Yes
No
Yes
No
",:::.' ..Weight;-. •, •
10
0
20
0
JlilC IlUIJlUwl Ul JLttllllO t\Jt ui\j*i\sii3 cu*u tuu,*v<^j*j vtiAAWiv. »*»»»»«• w»~«- ___-,., __ — ,_, j, „
different for broilers versus turkeys. 1997 Census of Agriculture data (USDOC, 1999) were used to determine the number of
farms in each state within the two size ranges, 300 to 1,000 AU and >1,000 AU.
k Components were assumed not to be required for states other than the 12 reviewed.
Technology Frequency Factors for Poultry and Swine
Data used to determine frequency factors for poultry and swine varied upon the
sector and component or practice. Industry and USDA data were used as the basis for most of
the frequency factors for layers (United.Egg Producers/United Egg Association and Capitolink,
1999) and swine (USDA APHIS, 1995 andNPPC, 1998), whereas analysis of state and federal
regulations was used primarily for broilers and turkeys. In addition, frequency factors were also
derived from data provided by USDA NRCS (2002) provided to EPA electronically on February
6,2002. USDA NRCS data included frequency factors for three performance-based categories of
facilities (low performing, medium performing, and high performing) for a series of
"representative" farms defined by USDA. Frequency factors are presented in Tables 6.4-2
through 6.4-8 for the various combinations of sector, region, size class, and performance level.
Literature and industry data for the broiler and turkey .sectors was generally not
detailed enough to generate frequency factors. Instead, EPA reviewed the specific regulatory
language and summaries of regulations for 12 major poultry-producing states regarding
requirements for nutrient management plans (NMPs) at broiler and turkey facilities (Tetra Tech,
2000). Requirements were considered for both medium and large facilities. All broiler and turkey
6-26
-------
facilities were assumed to use dry waste management systems. Erom the analysis of state and
federal regulations, EPA determined that a few states akeady require broiler and turkey facilities
to implement some of the components of a NMP. Except as specified for ground water and
surface water requirements, and in cases where select frequency factors could be based on
available industry data, the analysis from these 12 states were used to calculate regional frequency
factors. These state regulation based frequency factors approximate the number of facilities that
are currently required to implement NMP components and, therefore, must already incur costs for
these components. Weighted averages were used to estimate frequency factors for each
component. .
Assessment of Ground Water Link to Surface Water. The frequency factors
for these assessments at layer (United Egg Producers/United Egg Association and Capitolink,
1999) facilities was based upon industry data, while the frequency factors for broiler and turkey
facilities were conservatively assumed to be zero. The frequency factors for swine facilities was
based upon a review of state regulations that already require lagoons to be lined.
Surface Water Monitoring and O&M. The frequency factors for surface water
monitoring at layer facilities were assumed to be zero based on site visits, those for swine were
based upon industry data (USDA APHIS, 1995), and those for broiler and turkey facilities were
derived from an analysis of state regulations (Tetra Tech, 2000).
Soil Augers. The frequency factors for soil augers at layer (United Egg
Producers/United Egg Association and Capitolink, 1999) and swine (NPPC, 1998) facilities were
based upon industry data, while the frequency factors for broiler and turkey facilities were derived
from an analysis of state regulations (Tetra Tech, 2000). In cases where states require soil testing
at broiler and turkey facilities, it was assumed that soil augers (or an equivalent technology) are
also required or otherwise available to the facility, and thus not costed.
6-27
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Manure Sampler. The frequency factors for manure samplers at layer (United
Egg Producers/United Egg Association and Capitolink, 1999) and swine (NPPC, 1998) facilities
were based upon industry data, while the frequency factors for broiler and turkey facilities were
derived from an analysis of state regulations (Terra Tech, 2000). In cases where states require
manure testing at broiler and turkey facilities, it was assumed that manure samplers (or an
equivalent technology) are also required or otherwise available to the facility, and thus not costed.
Scales for Spreader Calibration. The frequency factors for calibration scales at
layer (United Egg Producers/United Egg Association and Capitolink, 1999) and swine (NPPC,
1998) facilities were based upon industry data, while the frequency factors for broiler and turkey
facilities were derived from an analysis of state regulations (Tetra Tech, 2000). In cases where
states require calibration of manure spreaders at broiler and turkey facilities, it was assumed that
calibration scales (or an equivalent calibration technology or method) are also required or
otherwise available to the facility, and thus not costed. Calibration of solid manure spreaders can
be performed in a number of ways, some of which are based on volume instead of weight, and
liquid-based systems can also be calibrated in terms of volume.
Initial NMP Development and NMP Recurring. The frequency factors for
development of an on-farm NMP at layer (United Egg Producers/United Egg Association and
Capitolink, 1999) and swine (USDA APHIS, 1995) facilities were based upon industry data, while
the frequency factors for broiler and turkey facilities were derived from an analysis of state
regulations (Tetra Tech, 2000). Revision of plans at broiler and turkey facilities was considered
to occur only if explicitly mentioned in the state regulations.
Calibration of Manure Spreader. The frequency factors for spreader calibration
at layer facilities were based upon industry data (United Egg Producers/United Egg Association
and Capitolink, 1999), those for swine facilities were based upon data from the AFO Strategy
(USEPA, 1999), and those for broiler and turkey facilities were derived from an analysis of state
regulations (Tetra Tech, 2000).
6-35
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Storm Water Diversions and Storm Water 6&M. The frequency factors for
storm water diversions at layer facilities (United Egg Producers/United Egg Association and
Capitolink, 1999) were based upon industry data, those for swine facilities were based upon site
visits, and those for broiler and turkey facilities were derived from an analysis of state regulations
(Tetra Tech, 2000). The frequency factors for operation and maintenance of field runoff controls
were assumed to-be equal to those for initial implementation of the controls.
Stream Buffer and>O&M. The frequency factors for stream buffers.at layer
facilities were based upon industry data (United Egg Producers/United Egg Association and
Capitolink, 1999), those for swine facilities were based upon site visits and state regulations, and
those for broiler and turkey facilities were derived from an analysis of state regulations (Tetra
Tech, 2000). .
Visual Inspection. The frequency factors for-visual inspection at .layer and swine
facilities were based upon the AFO Strategy (USEPA, 1999), while.the: frequency factors for
broiler and turkey facilities were derived from an analysis of state regulations (Tetra Tech, 2000).
*_*k * •*
Feeding Strategies. The frequency factors for feeding strategies at swine facilities
were based upon USDA data (USDA APHIS, 1995), while the frequency factors for broiler and
turkey facilities were provided by site visits and conversations with industry. Most broiler
facilities have phase diets, and an increasing number of broiler operations utilize feed additives
such as phytase. All broiler operations were all assumed to have phytase additions to their diet,
thus no benefit is observed. Phytase use is less common in turkey production where debates exist
that the skeletal structure of poults is affected by phytase interactions with calcium. EPA
assumed few if any layer facilities incorporated phased diets or feeding strategies beyond
nutritional requirements of the birds and molting (if any), and assumed the frequency factor was
zero.
Operations that Sell or Trade Manure. The frequency factors for the
percentage of swine operations that already sell, trade, or otherwise transport manure off-site for
swine is conservatively set to zero based on the small fraction of operations that report
6-36
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transporting manure off site (USDA APHIS, 1995). The frequency factors for poultry are based
on recent data submitted to the EPA (United Egg Producers, 2002).
Lagoon Marker. The frequency factors, for lagoon depth markers at swine •
facilities were based upon the AFO Strategy (USEPA, 1999). It was assumed that no layer
facilities had lagoon depth markers, and dry manure facilities do not need depth markers.
Adequate Storage, Soil Testing, Manure Testing, Record Keeping, Mortality
(Composting and O&M). The frequency factor for these components were primarily based on
data provided by USDA NRCS (2002). These frequency factors are from USDA's input files
entitled Summary ofCNMP needs and total cost per component for Manure and Wastewater
Storage and Handling provided to EPA electronically on February 6, 2002. The input file
includes frequency factors for three performance-based categories of facilities (low performing,
medium performing, and high performing) for a series of "representative" farms defined by
USDA. Data describing the exact methods for handling swine mortality were not available,
however, EPA believes all Large CAFOs already have technologies/BMPs in place to handle
routine mortalities. Since additional controls of mortalities were only considered for Option 3,
EPA only calculated incremental costs for those operations with a direct hydrologic link to
surface waters from the ground water beneath the production area. The portion of facilities
required to implement .additional swine mortality controls was based on an assessment of ground
water risk (USEPA, 2000). Thus, the frequency factors for swine mortality represent the percent
of operations that would not have to implement additional mortality practices because they do not
have a hydrologic link from the ground water to the surface water rather than the actual
percentage of swine operations that have adequate mortality handling facilities.
6.5
Poultry and Swine Nutrient Basis Frequency Factors
EPA estimated the number of facilities that will have to land-apply their manure on
a phosphorus basis by using state soil test data (Sharpley, A.N., T. Daniel, T. Sims, J. Lemunyon,
R. Stevens, R. Parry, 1999). Consistent with EPA acknowledgment of site-specific differences,
these data clearly show that high soil phosphorus levels are a regional problem. Distinct areas of
6-37
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general phosphorus deficit and surplus exist within states and regions and can be correlated to
areas of intensive animal production. To develop the percentage of agricultural soils testing high
in phosphorus on a regional basis, the percentage of soils testing high or above in phosphorus was
weighted with the number of facilities in each state. Table 6.5-1 shows the results of the facility-
weighted soil test values by region and animal type. The label "P" indicates that more than half of
the facility-weighted soils tested high or above, for phosphorus. An "N" indicates that less than
half of the facility-weighted soil tests in the region were high hi phosphorus. If the facility
weighted soil test values indicated that more than half of the soils in the region tested high for
phosphorus, it was assumed that 60 percent of the facilities will require a phosphorus-based
manure application rate and 40 percent can use a nitrogen-based rate. If the facility-weighted soil
.test values indicated that less than half of the soils in the region tested high for phosphorus, it was
assumed that 40 percent of the facilities will require a phosphorus-based manure application rate
and 60 percent can use a nitrogen-based rate. This approach reflects the potential fluctuations in
phosphorus soil tests in a given state. •
6-38
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Table 6.5-1
AFO Nutrient Management Planning Basis by Animal Sector and Region
Based on Percentage of Agricultural Soils Analyzed by Soil Test Laboratories
in 1997 That Tested High or Above for Phosphorus
Sector
Industry
Broilers
Layers (dry)
Layer (wet)
Swine"
Turkey
Broilers
Layers (dry)
Layers (wet)
Swine
Turkey
farm. Size
Medium
Medium
Medium
Medium
Medium
Large
Large
Large
Large
Large
Regions ' " ^
Central ,
P
P
N
N
N
P
P
P
N.
N
Mid-Atlantic
P
P
P
P
P
P
P
P
P
P-
Midwest
,P
P
P
P
P
P
P
P
P
P
Pacific .
> P
P
P
P
P
P
P
P
P
P
South
N
N
N
-P
P
N
N
N
P
P
Key: N = less than half of the facility-weighted soil tests in the region were high in phosphorus.
P = more- than half of the facility-weighted soils tested high or above for phosphorus.
6.6
Poultry and Swine Land Availability Frequency Factors
All operations fall into one of three land availability categories depending on the
amount of on-site cropland available for manure application.
Category 1 operations have sufficient land to land-apply all of then-
generated manure and wastewater at appropriate agronomic rates. No
manure is transported off site.
Category 2 operations do not have sufficient land to land-apply all of their
generated manure and wastewater at appropriate agronomic rates. The
excess manure after agronomic application is transported off site.
6-39
-------
Category 3 operations do not have any available land for manure
application. All generated manure and wastewater is transported off site.
For broilers and swine, the number of operations by land availability category was
provided by the USDA NRCS (2002) at the state or group-of-state level. Section 4.3 provides
details on how these data were processed for broilers and swine. For layers and turkeys, the
number of operations by land availability category was provided by USDA NRCS (2002) at the
national level by size class. Percentages were computed using the number of operations by land
availability category with the results provided in Table 6.6.1. Due to data disclosure issues the
number of Category 1 operations using a phosphorus based application rate was not made
available. Lacking this data, EPA heuristically assumed that 20 percent of the Category 1
operations using nitrogen based application rates would be Category 1 using phosphorus based
application rates.
Table 6.6-1
Percentage of Category 1,2, and 3 Operations for Layers and Turkeys
Sector
Layers
Layers
Layers
Layers
Layers
Turkeys
Turkeys
Turkeys
Turkeys
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Nitrogen Based Applications
Category 1
25.64%
19.28%
14.71%
10.88%
10.88%
16.11%
7.32%
10.69%
7.47%
Category 2
44.97%
40.36%
40.34%
41.43%
41.43%
53.03%
60.46%
53.05%
53.87%
Category 3
29.38%
40.36%
44.96%
47.69%
47.69%
30.86%
32.22%
36.26%
38.66%
Phosphorus Based Applications
Category 1
4.25%
3.86%
2.94%
2.18%
2.18%
3.22%
1.46%
2.14%
0.00%
Category2
66.37%
55.78%
52.10%
' 50.13%
50.13%
65.92%
66.32%
61.60%
61.34%
Category 3
29.38%
40.36%
44.96%
47.69%
47.69%
30.86%
32.22%
36.26%
38.66%
6-40
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6.7
Ground Water Control Frequency Factors
EPA developed two sets of frequency factors for all animal types for ground water
control costs. The first set of frequency factors corresponds to Options 3A/3B and includes
ground water monitoring, ponds and lagoons with engineered liners, concrete pads for solid waste
storage areas, and a hydrological assessment. The second set of frequency factors corresponds to
Options 3C/3D and includes permeability standards for waste storage units.
- - J EPA developed the frequency factors for Option -3A/3B using an analysis of soil
types ancfgrouhd water depths across the country (USEPA, 2000). Based on this analysis, EPA
determined that, under Option 3A/3B, facilities located in areas with sandy soils, shallow depths
to ground water, and karst or karst-like terrains would require ground water controls and all other
facilities would incur only the costs for the ground water assessment. Table 6.2-1 presents the
frequency factors for facilities located in areas requiring controls and facilities requiring only a
ground water assessment under Options 3A/3B.
Table 6.2-1
Percentage of Facilities Incurring Ground Water Costs Under Option 3A/3B
Animal
f:|[$pe .
All -
Size Class
All
Region
Central
Mid-Atlantic
Midwest
Pacific
South -
Facilities Requiring All
Ground Water Controls
13%
24%
27%
12%
22%
Facilities Requiring Only a •:
Hydrologic Assessment
87%
76%
73%
88%
78%
EPA developed the frequency factors for Option 3C/3D using an analysis of state
regulations. Facilities located in states with permeability standards for waste storage units and in
\
locations identified under Option 3A/3B as high-risk areas were assumed to already be in
compliance with Option 3C/3D and therefore would not incur costs. EPA determined that
6-41
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existing permeability standards applied only to large facilities and, therefore, assumed that all
medium facilities located in areas with a high risk of ground water contamination would incur
costs. To develop regional frequency factors for facilities that would incur costs under Option
3C/3D, EPA used the following equation: '.•.•_.
FacPermeability = (1 - %FacState) x %FacGW
[6-1]
where:
FacPermeability
%FacState
%FacGW
Percentage of facilities located in the region that
incur ground watercosts under Option 3C/3D
Percentage of facilities in the region that are located
in states with existing permeability standards -:
""Percentage of facilities in the region that are located
in areas with a .high risk of ground water
contamination.
Table 6.2-2 presents the percentage of facilities requiring ground water costs under Option
3C/3D.
6-42
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Table 6.2-2
Percentage of Beef Feedlots, Dairies, and Heifer Operations Incurring Ground
Water Costs Under Option 3C/3D
Animal Type
Size Class
Region
Central
Option 3C
Beef and Heifer
Dairy
Veal
Option 3D
Beef and Heifer
Dairy
Veal
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
13% '
6%.
13%
7%
13%
87%
94%
87%
93%
13%
, Mid-
Atlantic'
24%
20%
24%
22%
24%
76%
80%
76%
78%
24%
Midwest
27%
26%
27%
13%
27%
73%
74%
73%
87%
27%
Pacific
12%
10%
12%
12%
12%
88%
90%
88%
88%
12%
South
22%
22%
22%
22%
22%
78%
78%
78%
78%
22%
6-43
-------
6.8
References
ERG, 2000. State Requirements for Land Application at Agronomics Rates. January 13,2000".
ERG, 2001. Methodology to Incorporate USDA Frequency Factors into Beef and Dairy Cost
Model Methodology. December 2002.
Kellogg, R.et al., 2000. Manure Nutrients Relative to the Capacity of Cropland and Pdstureland
to Assimilate Nutrients: Spatial and Temporal Trends for the U.S.
MPPC. 1998. Environmental Assurance Program Survey. National Pork Producer Council.
Sharpley, A.N., T. Daniel, T. Sims, J. Lemunyon, R. Stevens, R. Parry, 1999. Agricultural
Phosphorus and Eutrophication. ARS-149. United States Department of Agriculture:
Agricultural Research Service. July, 1999.
Tetra Tech, Inc., 2000. Cost Model for Swine and Poultry Sectors. May 2000.
United Egg Producers, 2002. Statistics, http://www.unitedegg.org/statistics.htm, retrieved
11/7/2002.
United Egg Producers/United Egg Association and Capitolink, 1999. Data submission to EPA.
USDA, 1999. Fax from Lindsey Garber, USDA/NAHMS-Center for Animal Health Monitoring,
August 1999.
USDA, 2001. Estimation of Private and Public Costs Associated with Comprehensive Nutrient
Management Plan Implementation: A Documentation. April 23, 2001.
USDA APHIS, 1995. Swine '95. Part 1. Reference of 1995 Swine Management Practices.
USDA, Animal and Plant Health Inspection Service, National Animal Health Monitoring
System.
USDAARS, 1999. Agricultural Phosphorus and Eutrophication, ARS-149.
USDS NRCS, 2002. Summary ofCNMP needs and total cost per component for Manure and
Wastewater Storage and Handling. Electronic files received by EPA on February 6,
2002.
USEPA. 1999. State Compendium: Programs and Regulatory Activities Related to Animal
Feeding Operations - Interim Final Report. U.S. Environmental Protection Agency,
Office of Water, Washington, DC.
USEPA, 2000. Identification of Acreage of U.S. Agricultural Land with a Significant Potential
for Siting of Animal Waste Facilities and Associated Limitations from Potential of
6-44
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Groundwater Contamination-draft 12/15/99. Memorandum from Mike Clipper and Terry
Sobecki, EPA, to the Feedlots Rulemaking Record. October 3, 2000.
USEPA. 1999. Unified National Strategy for Animal Feeding Operations,
http://www.epa.gov/owm/finafost.htm. Accessed on September 23, 1999.
6-45
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7.0
EXAMPLE MODEL CALCULATIONS
This section includes an example calculation of model farm costs for the beef and
dairy cost model.
7.1
Beef and Dairy Model Farm Example Calculation
This subsection uses the information presented previously in this report to provide
an example calculation of model farm costs. The beef and dairy cost model calculates the total
model farm costs using the waste management system component costs with the frequency
factors. This subsection presents an example of this calculation for the following model farm for
Option 2:
Animal type = Dairy;
Size class = Large 1 (i.e., >700 head);
Regional location = Central;
Farm type = Flush; and
Performance level = Medium.
Under Option 2, the cost model estimates costs for a Large dairy operation in the
Central region for the following waste management system components:
Runoff control berms;
Concrete settling basin;
Lagoon;
Accumulated sludge removal;
Composting;
Liquid land application equipment;
Commercial fertilizer application;
Nutrient management planning; and
Off-site waste transportation.
This example does not show how each of these component costs is calculated.
Instead, this example uses these component costs (Appendix A) and frequency factors to calculate
the final weighted model farm cost.
7-1
-------
The costs presented in this example represent the expected costs for this model
farm for the final rule. Appendix C presents the model farm costs (in 1997 dollars) for Options 1,
2 and 5.
7.1.1
Unit Component Costs
The first step in the cost calculation is the generation of costs for each component
included in the regulatory option. As noted in Section 7.1, EPA is not showing how these costs
are calculated here; instead, these component costs are provided as the starting point for this
example. The methodology for calculating these costs is presented in corresponding sections of
this report.
Component costs are classified based on whether they vary by nutrient application
basis and land availability category. Nutrients may be applied on site according to either the
nitrogen needs of the crops or the phosphorus needs of the crops. Additionally, all model farms
are classified into three land availability categories:
Category 1 facilities have enough cropland to apply all of their waste on
site;
Category 2 facilities have some cropland, and apply some of their waste on
site and haul the other portion of waste off site; and
• Category 3 facilities have no cropland and haul all of their waste off site.
The cost model calculates costs for seven possibilities for each farm type, region,
size group, and performance level:
1) Component cost does not vary by nutrient basis or category;
2) Component cost varies by category and nutrient: Nitrogen basis, Category
1 facility;
3) Component cost varies by category and nutrient: Phosphorus basis,
Category 1 facility;
7-2
-------
4) Component cost varies by category and nutrient: Nitrogen basis, Category
2 facility;
5) Component cost varies by category and nutrient: Phosphorus basis,
Category 2 facility; <
6) Component cost varies by category and nutrient: Nitrogen basis, Category
3 facility; and
7) Component cost varies by category and nutrient: Phosphorus basis,
Category 3 facility.
The cost model calculates a weighted model summary cost for each category by summing the
component costs that do not vary with the category costs,"weighted according to the nutrient"
basis and category.
Table 7.1.1-1 presents component costs that do not vary by nutrient application
basis (i.e., nitrogen- versus phosphorus-based application). Table 7.1.1 ^presents component
costs that do vary by nutrient application basis. Finally, Table 7.1.1-3 presents the component
costs for the four transportation scenarios considered for both Category 2 and Category 3 flush
dairies.
Table 7.1.1-1
Component Costs for Option 2 That Do Not Vary by
Nutrient Application Basis
Flush Dairy, Large 1, Central
Component
Runoff control berms
Concrete settling basin
Lagoon
Accumulated sludge removal
Composting
Flush Dairy
Capital
$3,069
$130,713
$201,552
$122,426
$9,157
" "• Annual , ; -=•..-''"; -
$61.
$2,614
$10,078
$6,121
$7,995
7-3
-------
Table 7.1.1-2
Component Costs for Option 2 That Vary by Nutrient Application Basis
Flush Dairy, Large 1, Central
Nitrogen-Based Application
Capital
Fixed
Annual
Phosphorus-Based Application
Capital
Fixed •'•'.'• \. , > Annual :
Category 1 ,,,..., . • •
Nutrient Management
Planning
Commercial Nitrogen
Fertilizer
Liquid Land
Application
$0
$0
$70,454
$3,648
$0
$0
$2,453
$0
$7,510
. $0
$0
$125,115
$9,316
$0
$0
Category 2
Nutrient Management
Planning
Commercial Nitrogen
Fertilizer
Liquid Land
Application
$0
$0
$64,925
$2,151
$0
$0
$1,581
$0
$6,212
$0
$0
$104,562
$3,194
$0
$0
$5,750
$25,361
$11,541
$2,188
$7,300
$10,669
Category 3
Nutrient Management
Planning
Commercial Nitrogen
Fertilizer
Liquid Land
Application
$0
$0
$0
$1,035
$0
$0
$1,089
$0
$0
$0
$0
$0
$1,035
$0
$0
$1,089
$0
$0
NOTE: Nutrient Management Planning includes the following costs: nutrient plan development, soil and manure sampling,
land application equipment calibration, recordkeeping and reporting, lagoon depth markers, and identification of setback areas.
7-4
-------
Table 7.1.1-3
Transportation Costs for Option 2 Flush Dairy, Large 1, Central
iflCategory" v
2
3
Transportation
Scenario
Purchase truck
Contract haul
Purchase truck
(composted manure)
Contract haul
(composted manure)
Purchase truck
Contract haul
Purchase truck
(composted manure)
Contract haul
(composted manure)
Nitrogen-Based Application
Capital
$171,724
"~ $0
$171,724
$0
NA
NA
NA
NA
Annual
$21,932
$68,850
$21,909
$68,831
NA
NA
NA
NA
Phosphorus-Based Application
Capital
$373,312
-$o -
$373,312
$0,
$373,312
$0
$373,312
$0
Annual
$46,494
$30,400
$46,426
$30,363
$106,031
$130,758
$105,997
$130,751
'Category 1 operations do not incur transportation costs because they have sufficient land to apply all waste on site.
NA - Not applicable; Category 3 operations do not incur transportation costs under N-based scenarios because they are already
assumed to transfer all waste off site under N-based scenarios.
7.1.2
Calculation of Weighted Component Costs
The cost model then weights the component costs to reflect the percentage of
operations that already have some components in place. The following equation is used to weight
the component costs:
Costw<.rghttd = Costcomponcnt x (l . Frequency Factor)
[7-1]
where:
Costweighted
^ostcomponent
Frequency Factor
Weighted component cost
Component cost (from Table 7.1.1-1)
Percentage of operations that have component hi
place.
7-5
-------
Table 7.1.2-1 presents the frequency factors used for large flush dairy operations in
the Central region.
Table 7.1.2-1
Percentage of Operations Assumed to Have Equivalent Technology In Place
Flush Dairy, Large 1, Central
Component
Runoff control berms
Concrete settling basin
Lagoon
Accumulated sludge removal
Composting
Nutrient management planning
Commercial nitrogen fertilizer
Liquid land application
Transportation (N-Based)
Performance Category of Operation
High .
100%
33%
100%
100%
0%
20%
0%
90%
54%
Medium
90%
33%
100%
100%
0%
10%
0%
70%
54%
Low
70%
33%
100%
100%
0%
0%
0%
50%
54%
Equation 7-1 is used to calculate the weighted component costs for the model farm
for all land availability categories (Categories 1, 2, and 3) and performance categories (high,
medium, and low). For example, capital weighted costs for liquid land application in Category 2
at a medium performing facility are calculated as follows:
where:
$64,924
0.70
Costcomponent x (1 - Frequency Factor)
$64,925 x (1 - 0.70)
$19,477
Category 2 liquid land application cost, Table
7.1.1-2
Frequency factor for liquid land application from
Table 7.1.2-1.
7-6
-------
Table 7.1.2-2 presents the weighted component costs for components that do not
vary by nutrient application basis and land availability category-. Costs are shown for all
performance categories. Table 7.1.3-1 presents the weighted costs for components that vary by
nutrient application basis and land availability category.
Table 7.1.2-2
Weighted Component Costs for Option 2 That Do Not Vary by
Nutrient Application Basis and Land Availability Category
Medium Performance, Flush Dairy, Large 1, Central
Component
Runoff control berms
Concrete settling basin
Lagoon
Accumulated sludge removal
Composting
• " .. ' -' ., '-.'.'Capital '. •••'- :"VV:;f
$307
$87,578
$0
$0
$9,157
;ft:;;w;:-',":';;0-.::-v;:.;'AjbriuaI" "'. ' '. .. ...
$6
$1,752
$0
$0
$7,995 ;
7.1.3
Calculation of Weighted Farm Costs
Some weighted component costs vary depending on the nutrient application basis
and land availability category, as shown in Table 7.1.3-1. To calculate weighted farm costs, the
cost model applies farm-type frequency factors to the weighted component costs to represent the
portion of operations that can be characterized within each nutrient management basis and land
availability category.
7-7
-------
Table 7.1.3-1
Weighted Component Costs for Option 2 That Vary by
Nutrient Application Basis and Land Availability Category
Medium Performance, Flush Dairy, Large 1, Central
Component --
Nitrogen-Based Application
Capital Costs
•: Annual Costs
, Phosphorus-Based Application
Capital Costs
Annual Costs
Category 1 . ..' ..._..
Nutrient management planning
Commercial nitrogen fertilizer
Liquid land application
Transportation - Purchase truck option
Transportation - Contract-hauling option
Transportation - Purchase truck option with
composting
Transportation - Contract-hauling option
with composting
$3,283
$0 ,
$35,227
$0
$0
$0
$0
$2,207
$0
$3,755
$0 ,
$0
$0
0$0
$8,384
$0
$62,557
$0
$0
$0
$0
$5,175
$25,361
$5,771
$0
$0
$0
$0
Category 2
Nutrient management planning
Commercial nitrogen fertilizer
Liquid land application
Transportation - Purchase truck option
Transportation - Contract-hauling option
Transportation - Purchase truck option with
composting
Transportation - Contract-hauling option
with composting
$1,935
$0
$32,462
$171,724
$0
$171,724
$0
$1,423
$0
$3,106
$21,932
$68,850
$21,909
$68,831
$2,875
$0
$52,281
$373,312
$0
$373,312
$0
$1,969
$7,300
$5,335
$46,494
$30,400
$46,426
$30,363
Category 3
Nutrient management planning
Commercial nitrogen fertilizer
Liquid land application
Transportation - Purchase truck option
Transportation - Contract-hauling option
Transportation - Purchase truck option with
composting
Transportation - Contract-hauling option
with composting
$1,035
$0
$0
$0
$0
$0
$0
$1,089
$0
$0
$0
$0
$0
$0
$1,035
$0
$0
$373,312
$0
$373,312
$0
$1,089
$0
$0
$106,031
$130,758
$105,997
$130,751
7-8
-------
The first farm-type weighting factor applied adjusts the weighted component costs
" i *
for the land availability category (Category 1, Category 2, or Category 3). Section 6.0 presents
the calculation of the land availability category frequencies, and Table 7.1.3-2 provides these
frequency factors for dairies under the nitrogen-based and phosphorus-based application
scenarios.
Table 7.1.3-2
Land Availability Category Frequency Factors
Dairies, Large 1
Category 1
Category 2
Category 3
.Nitrogen Basis
27%
51%
22%
Phosphorus Basis
10%
68%
22%
The second farm-type weighting factor applied adjusts the weighted component
costs for the type of nutrient-based application used. Because all operations are required to land
apply using a nitrogen-based application rate under Option 1, the weighted farm costs are equal to
the nitrogen-based weighted component costs. Likewise, because all operations are required to
land-apply using a phosphorus-based application rate under Option 2A, the weighted farm costs
are equal to the phosphorus-based weighted component costs. For the remaining options, EPA
assumed that each model farm would apply waste based on both a nitrogen and phosphorus basis.
Section 6.0 presents the percentage of costs that are attributed to an N-based application basis
versus a P-based application basis for each model farm. For this example, the nutrient-based
frequency factors for large dairies in the Central region are 56 percent of operations require
nitrogen-based application and 44 percent of operations require phosphorus-based application.
The cost model uses these two farm-type factors to calculate the weighted farm
costs using the following equation:
7-9
-------
Category
= [(%N x Q/oN-Cat X x Catl(N)Costj + (%P x %P-Cat X x Catl(P)Cost)]
[(%N x %N-Cat X) + (%P x o/oP-Cat X)]
where:
%N
%N-CatX
%P
%P-CatX
Percentage of land that requires N-based application
Category X frequency factor under an N-based
application scenario
Percentage of land that requires P-based application
Category X frequency factor under an P-based
application scenario.
For example, capital weighted costs forliquid land application in Category 2 at a
medium-performing facility~are calculated as:
Land Application,
Icat2
= [(56% x 54% x $19,477) + (44% x 68% x $31,369)]
[56% x 54% + 44% "x 68%]
[7-4]
The cost model uses each of the weighted model farm components to calculate the
weighted model farm costs using Equation 7-3 for each possible category and transportation
option. The transportation cost test is then used to determine which transportation option is the
least costly, as described in Section 5.17 of this report. The selected transportation option for this
example is contract hauling without composting for both Category 2 and 3 operations.
Table 7.1.3-3 presents the weighted farm costs for the example model, including
the selected least-cost transportation scenario.
7-10
-------
Table 7.1.3-3
Weighted Farm Costs for Option 2
Medium Performance, Flush Dairy, Large 1, Central
; Component
Concrete.basin
Berms ; .,'.
Composting11
Lagoon
Nutrient management
planning0 --••-•-•-•
Liquid land
application
Commercial fertilizer
application
Category!:
Capital
$87,578 '
' $307
$0
.$0
$4,433
$24,833
$0
Annual
$1,752
$6
$0
$0
$2,877
$2,526
$5,717
Category 2
Capital
$87,578
$307
$0
$0
$2,416
$25,561
$0
Annual
, $1,752
$6
..- $0
$0
$1,702
$2,548
$3,735
Category 3
Capital
$87,578
$307
$0
$0
$1,035
$0
$0
Annual
$1,752
$6
$0
$0
$1,089
$0'
$0
Selected Transportation Scenario .
Purchase truck
$0
$0
$0
$49,178
$0
$57,533
"Costs are weighted by farm type (hose versus flush) and by application basis (nitrogen versus phosphorus).
""Composting costs were not selected as part of the model farm costs.
'Nutrient management planning capital costs are fixed costs; 3-year recurring costs are also incurred, but are not shown in this
table.
7.1.4
Final Model Farm Costs
The weighted farm costs are summed and annualized for each of the transportation
scenarios, and the least costly scenario is selected. The cost model sums these costs to generate
the final model farm capital, annual, fixed, and 3-year recurring costs by category. Table 7.1,4-1
presents the weighted farm costs selected for the model farm. Commercial fertilizer costs are
listed as a separate cost item in the model farm result tables presented in Appendix C.
7-11
-------
Table 7.1.4-1
Model Farm Costs by Category
Medium Performance, Flush Dairy, Large 1, Central
Component
Category 1
Total Model Farm Costs
Commercial Fertilizer Application
Category 2 -
Total Model Farm Costs
Commercial Fertilizer Application
Category 3
Total Model Farm Costs
Commercial Fertilizer Application
Capital
$112,718
$0
$113,446
$0
™- , w:^ _**«^ .- ,">..w r**-'.. •-',_'," •,'.-. . iA
' "$87,885-
$0
Annual
_
$56,658
$5,717
'
$63,731
$3,735
SM.'^.ai-a^;^- ' - .-SiiV : -* - -' ,"'• "- ^-.''v
$2,968
$0
Fixed
$4,926
$0
, 4 „
$2,685
$0
;:*:;• *!;g;^.;? ' ' .; •;•,
$1,150
$0
7.2
Swine and Poultry Model Farm Cost Example
This section uses the information presented previously in this report to provide an
example calculation of model farm costs. The total model farm costs are calculated using the
waste management system component costs with the frequency factors. This section presents an
example of this calculation for the following model farm for Option 2 (manure land-applied on a
P-basis):
Animal type = Swine;
Size class = Large 1 (i.e., 2,500 to 4,999 head);
Regional location = Mid-Atlantic;
Farm type = Grow-Finish;
Waste storage system = lagoon; and
Performance level = Medium.
Under Option 2, the following components are costed for the above model farm:
Nutrient management planning (NMP) one time costs (soil auger, manure
sampler, scales for manure spreader calibration, initial NMP development).
7-12
-------
• NMP reoccurring costs (on-farm NMP development every 5 years, soil
testing every 3 years).
• NMP annual costs (record keeping, manure spreader calibration, manure
testing twice per year).
• Facility upgrades (lagoon depth marker, berms to divert storm water from
entering lagoon, field runoff controls).
• Facility annual costs (visual inspection, operation and maintenance of
berms, operation and maintenance of field runoff controls, and land rental
value).
• Practices to remove excess manure nutrients from the operation site
(secondary lagoon to decrease dilution and the least expensive scenario of
the following: feeding strategies; hauling, with or without feeding
strategies; solid liquid separation and hauling, with or without feeding
strategies; retrofit to scraper system and hauling, with or without feeding
strategies; retrofit to high rise and hauling, with or without feeding
strategies; retrofit to hoop house and hauling, with or without feeding
strategies; sludge cleanout every 5 years, with or without feeding
strategies). ,
• Commercial fertilizer costs that replace manure nutrients in some
situations.
The methodologies used to calculate the costs for each of these waste management
system components are presented in Chapter 5. This example demonstrates how these
methodologies are used to calculate the costs for one model farm. This example also demonstrates
how the frequency factors are used to calculate the final, weighted, model farm cost.
7.2.1
Unit Component Costs
As in the previous dairy example, the first step in the cost calculation is the
generation of costs for each component included in the regulatory option. This example does not
include calculating the component level costs; instead, these component costs are provided as the
starting point for this example. The methodology for calculating each of these costs is presented
in corresponding chapters of this report.
Component costs are classified based on whether they vary by nutrient application
basis and land availability category. Nutrients may be applied on site according to either the
nitrogen needs of the crops or the phosphorus needs of the crops (the examples below assume
7-13
-------
that manure nutrients are applied to meet the phosphorus needs of the crops). Additionally, all
model farms are classified into three land availability categories:
Category 1 facilities have enough cropland to apply all of their manure .
nutrients on site;
• Category 2 facilities have some cropland, and apply some of their manure
._.. ._.. nutrients on site and can use a variety of practices to remove the remaining
manure nutrients; and_,, ., , . _„ ......
"•"" ' i Category 3 facilitiesTha've no cropland and"must remove excess manure
„—~ --'nutrients from the operation site. •- •.
Costs are calculated for six possibilities for each farm type, region, size group, and
performance level:
1) Component cost that do not vary by nutrient basis and category;
2) Component costs that do not vary for facilities that apply manure on site;'
3) Component costs that vary in direct proportion to the number of animals at
the facility;
4) Component costs that vary by the acreage at the facility (Category 1 and 2
facilities);
5) Component costs for Category 2 facilities that vary by regulatory option;
and
6) Category 3 facility costs for moving manure nutrients an additional distance
under option 2.
A weighted model summary cost is calculated for each category by summing the component costs
that do not vary with the category costs, weighted according to the nutrient basis and category.
Table 7.2-1 presents component costs that do not vary by option, facility category,
or nutrient application basis (i.e., nitrogen- versus phosphorus-based application). Table 7.2-2
presents component costs that do vary for facilities that apply manure on-site. Table 7.2-3
presents the component costs that vary only based upon the number of head at the facility. Table
7-14
-------
7.2-4 presents component costs that vary by the acreage at the facility (Category 1 and 2
facilities). Table 7.2-5 presents component costs for Category 2 facilities that vary by regulatory
option.
Table 7.2-1
Component Costs for That Do Not Vary by Option, Fadlity Category, or
Manure Nutrient Application Basis
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
Component
Manure sampler
Record keeping
Lagoon depth marker
Manure testing
Visual inspection
Capital - ' \
$30
None
$30
None
None
" Annual
None
$1,020
None
$100
$130
Table 7.2-2
Component Costs That Do Not Vary for Facilities
That Land Apply Manure On-site
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
; Component ?
Soil auger
Two scales for spreader calibration
Calibrate manure spreader
Capital
$25
$500
None
. Annual : • • .'7- '.'.'"'
None
None
$40
7-15
-------
Table 7.2-3
Component Costs That Vary by Facility
Based on Head Count
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
Model Farm Description
Number .
of Head
Storm Water'Djversions (berms)
•-','• Capital
• ' Annual
Category 1 .._......
Option 1 (N-based application)
Option 2 (P-based application)
2,664
2,500
$816 ~
$795
$16
$16
Category 2 -
N-based application
P-based application
4,581
4,581
$863
$863
$17
$17
Category 3
All options
4,424
$1,008
$20
7-16
-------
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Unique Category 2 Facility Costs
Practices that reduce or remove excess manure nutrients are only used for
Category 2 facilities. The least expensive scenario of the following is selected:
Feeding strategies;
Install secondary lagoon to reduce manure dilution and hauling with or
without feeding strategies; * .
. Solid liquid separation and hauling withuor without feeding strategies;
• Retrofit to scraper system and hauling with or without feeding strategies;
• Retrofit to high rise and hauling with or without feeding strategies;
• Retrofit to hoop house and hauling with and without feeding strategies; or
• Install secondary lagoon to reduce manure dilution and sludge cleanout and
hauling every five years with and without feeding strategies.
Under option 2, Category 2 facilities that are required to apply their manure on site
using P-based application rates incur costs to apply commercial fertilizer. Table 7.2-5 presents
the unique component costs for Category 2 facilities by manure nutrient application basis.
7-18
-------
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11
-------
Category 3 Facility Costs for Option 2 P-based Manure Application
Under option 2 (P-based land application) Category 3 facilities are assumed to haul
their manure farther than they do under option 1 (N-based application) because more land is
required. As stated previously, facilities are assumed to apply their manure off site on a N-basis.
Thus it is assumed that costs are only applicable to the regulation for moving manure from
Category 3 facilities under option 2. The costs are calculated by multiplying the additional mileage
by the commercial hauling rate and the mass of the manure to be hauled. The model selects the
least expensive practice for moving the manure nutrients the additional distance from the facility.
The least expensive practice for Category 3 grow-finish facilities under option 2 in the Mid-
Atlantic region is hauling lagoon sludge every 5 years at a cost of $8,496.
7.2.2
Calculation of Adjusted Component Costs
As stated in section 7.1, the component costs are then adjusted to reflect the
percentage of operations that already have some components in place. The following equation is
used to adjust the component costs:
Costadjusted = Costcomponent x (1 - Frequency Factor)
where:
Costcomponent
Frequency Factor
Adjusted component cost
Component cost
Percentage of operations that have component in
place.
Table 7.2-6 presents the frequency factors used for Large 1 grow-finish operations
in the Mid-Atlantic Region.
7-20
-------
Table 7.2-6
Percent Operations Assumed to Have Equivalent Technology In Place
Swine Grow-Finish Operations with Lagoons, Large 1, Mid-Atlantic Region
" ~\'f '.'.-,..' 'Component - •-
Soil auger ••-•- -.„..„.,
Manure sampler ..... . ...... ._.
Scales for manure spreader calibration
Development NMP initial and recurring
Calibration of manure spreader
Visual inspections
Soil testing ~ " -
Manure testing -• -• - - •• • .-.,.-,
Recordkeeping _ .._.._ ..._.._
Lagoon depth marker
Stream buffers and O&M
Feeding strategies
Runoff control berms
Runoff control berm O&M
Transportation (N-Based)
Performance Category of Operation*
High
100% -•-•
.100%.,._
100% "_
100%
100%
100%
20%"
20%
.-,,20%™. .
100%
100%
100%
100%
70%
100%
Medium
98%
94% ..
94%
89%
100%
0%
10%
10%
.... 10%
100%
100%
95%
50%
1%
100%
Low
80%
0%
0%
0%
96%
0%
0%
0%
0%
96%
96%
0%
0%
0%
98%
: H = the high performing facilities (top 25%), M = the medium performing facilities (middle 50%, and L = the
low performing facilities (bottom 25%).
Equation 7-2 is used to calculate the adjusted component costs for each model
farm. For example, the annual costs for recordkeeping at a Category 2 medium performing
facility are calculated as follows:
where:
$1,020
0.10
Costadjusted = Costcomponent x (1 - Frequency Factor)
= $ 1,020 x(l-0.10)
= $918
Annual recordkeeping costs from Table 7.2-1.
Frequency factor for medium performer from Table 7.2-6.
7-21
-------
Table 7.2-7 presents the adjusted component costs for components that do not
vary by nutrient application basis and land availability category. Costs are'shown for all
performance categories. Table 7.2-8 presents the adjusted component costs for components that
do not vary for facilities that apply manure on site. Table 7.2-9 presents the adjusted component
costs that vary only based upon the number of head at the facility. Table 7.2-10 presents adjusted
component costs that vary by the acreage at the facility (Category 1 and 2 facilities). Table 7.2-
11 presents adjusted component costs for Category 2 facilities that vary by regulatory option.
Note that the frequency factors for Category 2 facilities that already reduce or remove excess
manure nutrients is zero for high, medium, and low performance facilities. It is also assumed that
no facilities use commercial N on site (zero frequency factor). Thus the costs do not vary by
performance level.
Table 7.2-7 ,
Adjusted Component Costs That Do Not Vary by Option, Facility Category, or
Manure Nutrient Application Basis
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
Component
Manure sampler
Record keeping
Lagoon depth marker
Manure testing
Visual inspection
• ;. - Capital ;-•; ••: •':••:•.'
H
$0
$0
$0
$0
$0
• 'M " .;
$1
$0
$0
$0
$0
L ''•• ;
$6
$0
$1
$0
$0
:•• '::':--'"-:- Annual '•••"'••• - '•'.'.; •;
'' ",
-------
Tablfe 7.2-8
Adjusted Component Costs for Option 2 That Do Not Vary for Facilities
That Land Apply Manure On Site
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
Component
Soil auger
Two scales for manure
spreader calibration
Calibrate manure spreader
Capital'- --•' /
H
$0
$0
$0
->M'X;V;-f
$1
$31
.$0
... ' L
$5
$500
$0
Annual
~ TT
$0
$0
$0
M "
$0
$0
$0
"L
$0
$0
$2
7-23
-------
Table 7.2-9
Adjusted Component Costs That Vary by Facility
Based on Head Count
Swine Grow-Finish with Lagoons, Large 1, Mid-Atlantic
Model Farm Description
Number
of Head
Category 1 , , - . I,
Option 1 (N-based
application)
Option 2 (P-based
application) *
2,664
2,500
Category2 , ,: ,\ ' :
N-based application
P-based application
4,581
4,581
Category 3 i
All options
4,424
Storm Water Diversions (berms)
- - .Capital
H_
$0
$0
• : H :
$0
$0
; .'BM-.
$0
.. M
$408
$398
' •' :M'O
$432
$432
. M >
$504
". L
$816
$795
•--' • > •t;,"
$863
$863
•.;;-,;..t;.-;.
$1,008
Annual
- M
$5
$5
,';i !••;.•>«.-;;
$5
$5
_,AV >&..:•
$6
M
$16
$16
•'..:'• •^-•'•,
$17
$17
: :v~M •'."•'•
$20
L
$16
$16
'.;',";•&•';
$17
$17
. •:. '_ '. 'L. ,
$20
7-24
-------
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7-26
-------
7.2.3
Calculation of Weighted Farm Costs by Nutrient Application Basis for
Option!
The final step in calculating farm costs is to weight the adjusted component costs
depending on the nutrient application basis. To calculate weighted farm costs, frequency factors
are applied to the adjusted component costs to represent the portion of operations that use each
nutrient management basis as shown in Table 7.2-12. Because all operations can land-apply using
a nitrogen-based application rate under Option 1, the weighted farm costs are equal to the
nitrogen-based weighted component costs. Likewise, because all operations are required to land-
apply using a phosphorus-based application rate under Option 2A, the weighted farm costs are
equal to the phosphorus-based weighted component costs. For the remaining options, it is
assumed that model farms would apply waste based on a weighted nitrogen and phosphorus basis.
For this example, the nutrient-based frequency factor for a large 1, swine, grow-finish operation in
the Mid-Atlantic Region is 60 percent of operations use phosphorus-based application and 40
percent of the operations use nitrogen-based application. This frequency factor is applied such
that the total number of category 1, 2, and 3 facilities that apply manure on a P-basis is equal to
60 percent of the total facilities.
Table 7.2-12
Assumed Nutrient Land Application Frequency For
Total Facilities For Key Swine Regions Under Option 2
Key Regions • ' . .
Mid-Atlantic
Midwest
Nitrogen Basis ;
40%
40%
Phosphorus Basis
60%
60%
The weighted farm costs using the following equation:
Costweighted = (Cost N x o/oN) + (Cost P x %P)
7-27
-------
where:
%N
Costs N
%P
Costs,
Percent of total facilities by performance level and
facility category that are required to use N-based
application
Adjusted component costs of N-based practice
Percent of total facilities by performance level and
facility category that are required to use P-based
application
Adjusted component costs P-based practice.
For example, the weighted costs for initial NMP development at a Category 2
facility, medium performing facility are calculated as:
V L
CqstBdgteI. =.($150 x (26/77))-)-($202 x (51/77)) .
= $50.65+ $133.79
= $184.44
7.2.4
Final Model Farm Costs
The weighted farm costs are summed for each option, facility type, size, land
availability category, and performance level. The final model farm costs are summed separately
for capital, fixed, annual, 3-year recurring, and 5-year recurring costs. Table 7.2-13 presents the
weighted farm costs for the model farms presented in this example. A complete lists of the costs
of the swine and poultry model farms is presented in Appendix C.
7-28
-------
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7-29
-------
-------
8.0
SENSITIVITY ANALYSES
The model-farm approach that EPA used to estimate costs for this regulation
provides an average cost that a facility is projected to incur under the regulatory options. As
discussed in Section 6.0, EPA used frequency factors to reflect baseline industry conditions for
high-, medium-, and low-performing farm operations. For example, some facilities may already
meet the proposed regulatory requirements; therefore, those facility costs will be zero.
Alternatively, some facilities may currently meet very few of the proposed regulatory
requirements, and these operations will incur costs that are much higher than the average model
facility cost. By estimating compliance costs for each type of operation, EPA has effectively
calculated the range of costs that would be incurred by facilities within each model farm.
Following the calculation of costs for each option, EPA performed sensitivity
analyses on the cost model to identify major drivers for the model farm costs under various
scenarios. EPA performed several sensitivity runs. These sensitivity analyses included the
following modifications of the regulatory options:
• For Option 1 A, EPA evaluated the costs associated with including capacity
for a chronic storm event for all animal operations with liquid storage;
• EPA conducted a cost driver analysis on Options 2 and 5 to determine
which waste management components were the major contributors to costs
for beef feedlots, dairies, and heifer and veal operations;
• For Option 2A, EPA evaluated the costs associated with requiring all
facilities to apply manure on an agronomic phosphorus basis for beef, dairy,
heifer, and veal operations; and
« For Option 2B, EPA evaluated the costs associated with requiring the
development of nutrient management planning for off-site manure
recipients for beef feedlots, dairies, and heifer and veal operations.
8-1
-------
8.1
Option 1A
The cost basis for all of the regulatory options evaluated for this rulemaking
includes liquid storage capacity for a 25-year, 24-hour rainfall event. In addition to this rainfall
event, the cost basis for Option 1A includes liquid storage capacity for a chronic storm event,
classified as a 10-year, 10-day storm. Because there is a higher chance of a 10-year, 10-day storm
event occurring in any given year, they have a higher amount of precipitation associated with
them than 25-year, 24-hour rainfall events. The 10-year, 10-day storm event can make a
difference of two inches or more per rainfall. If a lagoon or pond is only sized to contain process
wastewater plus the runoff from a 25-year, 24-hour rainfall event, there is a greater chance of
wastewater overflows due to a chronic storm event.
EPA assumes that facilities that require liquid storage as well as facilities that
already have liquid storage incur costs to construct and maintain additional capacity to contain
precipitation and runoff from the 10-day, 10-year chronic storm event.
Facilities with no existing liquid storage: Under Option 1 A, lagoon and ponds
are sized for facilities that require new liquid storage to account for 6 months of
average precipitation, the peak storm event (25-year, 24-hour rainfall event), and
the chronic storm event (10-year, 10-day). Both direct precipitation and runoff
resulting from the precipitation are included in the capacity of the lagoon or pond.
Facilities with existing liquid storage: Under Option 1 A, additional lagoon or
pond storage is sized for facilities that are assumed to already have liquid storage
to account for the 10-year, 10-day storm event. Both direct precipitation and runoff
resulting from precipitation are included in the additional capacity of the pond or
lagoon.
The increase in wastewater volume also affects the calculation of costs for liquid
land application and transportation. These are waste management components downstream of the
lagoon or pond that are dependent on liquid volume.
80
-2.
-------
The model facility costs are significantly higher for Option 1A as a result of
including capacity for the chronic rainfall event, ranging from 10 percent to multiple times the
cost of Option 1. si
8.2
Cost Driver Analysis
EPA performed an analysis on Options-2 and 5, as well as Option 3, to determine
the primary cost drivers under each regulatory scenario for the beef, dairy, heifer, and veal animal
groups. EPA used the weighted model farm output from the cost model to compare the weighted
cost of each component that comprised the model farm costs. Table 8.2-1 summarizes the results
of this analysis.
Additionally, EPA performed two sensitivity runs to identify the cost drivers for
the swine and poultry cost model: the first compared the effects of nitrogen-based nutrient
management verses phosphorus-based nutrient management on the costs, and the second •
compared the effects of ground water monitoring requirements on the costs. By running the
model both with and without frequency factors, EPA was able to identify the costs of the
technologies and practices that are most sensitive to the Agency's modeling assumptions. EPA
was then able to identify the model elements and cost components that were cost drivers and
would thus merit further analysis: the availability of cropland for manure utilization, the
incremental costs of phosphorus-based application over nitrogen-based application, the costs of
ground water controls, and the costs of incremental storage for timing constraints.
EPA had already developed an approach to reflect nitrogen- and phosphorus-based
requirements and had developed three categories of land availability to capture the wide range of
land application and hauling costs. EPA's sensitivity analysis concluded that the costs generated
by the refined cost models were stable over a wide range of modeling. To further examine the
cost impacts under different financial assumptions, such as varying revenue, farm performance,
and net returns, EPA conducted sensitivity analyses.
8-3
-------
Table 8.2-1
Results of Cost Driver Analysis
Animal
Beef
Dairy
Heifers
Veal
Size
Large
Medium
Large
Medium
Large
Medium
Medium
Option
2
Ground water
2
Ground water
2
Ground water
2
Ground water
2
Ground water
2
Ground water
5
Primary Driver(s)'
Nutrient management planning/transportation
Clay-lined pond/ Transportation/concrete pad
Nutrient management planning/land application
Nutrient management planning/land application/clay-lined pond
Concrete settling basin/transportation
Clay-lined lagoon/transportation
Nutrient management planning/transportation
Clay-lined lagoon/nutrient management planning
Nutrient management planning/transportation
Nutrient management planning/land application/clay-lined pond
Nutrient management planning/land application
Nutrient management planning/land application
Covered lagoon
a All drivers are listed that make up the top 50% of costs.
8.3
Option 2A
Under the regulatory options, facilities will be required to follow either nitrogen-
based nutrient management or phosphorus-based nutrient management. More cropland is
required to land apply manure waste at agronomic phosphorus-based rates than nitrogen-based
rates; therefore, phosphorus-based nutrient management incurs more costs for land application,
irrigation, nutrient management planning, and off-site transportation of manure waste than
nitrogen-based nutrient management.
To evaluate the significance of the nutrient application basis on the costs, EPA
performed a sensitivity analysis named Option 2A, based on Option 2. Option 2 costs are based
8-4
-------
on a combination of nitrogen-based and phosphorus-based nutrient management. Option 2A
represents a modification of this option by assuming 100 percent of facilities would be located in a
phosphorus-based nutrient management area. " --•-
!i r .
Because more cropland is required for phosphorus-based application, operations
that are Category 1 operations under nitrogen-based nutrient management may be reclassified as
Category 2 operations under phosphorus-based nutrient management. That is, a facility with
enough land to apply all of the manure waste on site under nitrogen-based application may not
-have enough land to apply all of their manure waste on site under phosphorus-based nutrient
management. Because of this, the most dramatic comparison of the effects of changing the
agronomic basis from nitrogen to phosphorus is seen by comparing the results of Option 1 (NT-
based application), Category 1 facilities to the sensitivity run for Option 2A (P-based application),
Category 2 facilities. • •- '- ~- ---
Comparing these results shows an increase of between 200 to 500 percent in the
costs from Option J, Category 1 to Option 2A, Category 2 for most model farms. This increase is
due to the following factors:
Shift in the number of facilities from Category 1 to Category 2 (thereby
incurring transportation costs);
A portion of Category 2 facilities under N-based application are assumed
to not incur transportation costs because they already apply manure at N-
based rates, while they do incur these transportation costs under P-based
application; and
Larger acreage for phosphorus-based facilities, requiring more irrigation,
soil sampling, and nutrient management planning costs.
8.4
Option 2B
Under the regulatory options, facilities will be required to design and implement a
nutrient management plan for the use of manure waste on site. EPA performed a sensitivity
8-5
-------
analysis to assess the estimated cost of developing a nutrient management plan for the use of
manure off site as well as on site. The cost model assumed that off-site recipients of manure
waste would apply the waste on a nitrogen-based agronomic basis.
The cost of a nutrient management plan is based on the number of acres on which
manure waste would be applied. Therefore, the cost model calculated the cost of the off-site
nutrient management plan by first estimating the amount of manure waste that would be
transported off site, then the nutrient content of that waste, and finally, estimating the agronomic
rate of application on a nitrogen basis. The cost model used these data to calculate the number of
acres required to land apply all of the waste transported off site on a nitrogen basis. This acreage
was the basis for the off-site nutrient management plan development costs.
The resulting cost to develop a nutrient management plan for recipients of waste
transported off site was insignificant compared to the total weighted model farm cost, typically
less than 5 percent of the weighted model farm cost.
8.5
Applications to Frozen Ground
Winter is the least desirable time for land application of manure. Although there
are some benefits to winter applications of manure, the negative impacts outweigh the advantages.
Winter applications might be advantageous because of greater labor availability and improved
driving capabilities on frozen soils. In addition, although there may be significant losses of
available nitrogen, the organic fraction will still be available for plant uptake. However, applying
manure in winter creates a potential for nutrient runoff because the manure cannot be
incorporated into frozen soil. Winter manure applications should include working the manure into
the soil either by tillage or by subsurface injection to reduce the runoff potential. Another
disadvantage of whiter manure application is low nutrient utilization during the winter months.
In northern areas where frozen soil and snow cover are common conditions, winter
manure application should be avoided. In fact, winter manure application is prohibited in a
8-6
-------
number of northern states and in most Canadian provinces. There may be some justification for
winter manure application, such as reduced ammonia volatilization and odor problems (Steenhuis,
T.S., G.D. Bubenzer, and J.S. Converse, 1979), reduced runoff due to a mulching effect of solid
manure (Young, R.A. and R.F. Holt, 1977; Clausen, J.C., 1990), enhanced die-off of some
microorganisms in freeze-thaw cycles (Kibby, H.J., C. Hagedom, and E.L. McCoy, 1978;
Stoddard et al. 1998), avoidance of soil compaction, and simplified farm management schedules.
However, considerable research has demonstrated that runoff from manure application on frozen
or snow-covered ground has a high risk of negative water quality impact.
Extremely high runoff N and P concentrations have been reported from plot
studies of winter-applied manure. Runoff concentrations as high as 23.5-1086.0 mg TKN /L and
1.6-15.4 mg TP/L have been observed (Thompson, D.B:, T.L. Loudon, and J.B. Gerrish, 1979;
Melvin, S. and J. Lorimor, 1996). In two Vermont field studies, Clausen (Clausen, J.C., 1990;
Clausen, J.C., 1991) reported the following nutrient increases hi runoff resulting from winter
application of dairy manure:
• - 165%-224% in total P concentrations;
• 246%-1480% in soluble P concentrations;
• 114% in TKN concentrations; and
Up to 576% in NH3-N.
Runoff mass losses of up to 22 percent of applied N and up to 27 percent of
applied P from whiter-applied manure have been reported (Midgeley, A.R. and D.E. Dunklee,
1945; Hensler, R.F., R.J. Olsen, S.A. Witzel, O.J. Attoe, W.H. Paulson, and R.F. Johannes, 1970;
Phillips, P.A., A.J. MacLean, F.R. Hore, F.J. Sowden, A.D. Tenant, and N.K. Patni, 1975;
Converse, J.C., G.D. Bubenzer, and W.H. Paulson, 1976; Klausner, S.D., PJ. Zwerman, and
D.F. Ellis, 1976, Young, R.A. and C.K. Mutchler, 1976, Clausen, J.C., 1990; Clausen, J.C., 1991;
Melvin, S. and J. Lorimor, 1996). Much of this loss can occur in a single storm event (Klausner,
S.D., P.J. Zwerman, and D.F. Ellis, 1976). Such losses may represent a significant portion of
annual crop nutrient needs.
8-7
-------
Runoff from winter-applied manure can be a major source of annual nutrient
loading to water bodies. In a Wisconsin lake, 25 percent of the annual P load from animal waste
sources was estimated to be from manure applied in winter (Moore, I.C. and F.W. Madison,
1985). In New York, snowmelt runoff from winter spreading on cropland contributed more P to
a local reservoir than did runoff from poorly managed barnyards (Brown, M.P., P. Longabucco,
M.R. Rafferty, P.D. Robillard, M.F. Walter, and D.A. Haith, 1989). Clausen and Meals (1989)
estimated that 40 percent of Vermont streams and lakes would experience significant water
quality impairments from the addition of just two winter-spread fields in their watersheds.
Winter application of manure results in increased microorganism losses in runoff
from agricultural land (Reddy, K.R., R. Khaleel, andJM.R- Overcash, 1981). Studies have shown
that cool temperatures enhance survival of fecal bacteria (Reddy, K.R., R. Khaleel, and M.R.
Overcash, 1981, Kibby, H.J., C. Hagedorn, and E.L. McCoy, 1978). However, research results
are conflicting; some researchers have reported that freezing conditions are lethal to fecal bacteria
(Kibby, H.J., C. Hagedorn, and E.L. McCoy, 1978, Stoddard et al. 1998). Kudva et al. (1998)
found that E. coli can survive longer than 100 days in frozen manure at -20 degrees C.
Vansteelant (2000) observed that freezing and thawing of a soil/slurry mix reduced E. coli levels
by about 90 percent. Research has found that winter application of manure does not guarantee
die-off of Cryptosppridium oocysts (Carrington, E.G. and M.E. Ransome, 1994; Payer, R. and T.
Nerad, 1996).
Furthermore, microorganism losses in winter application are increased due to the
lack of incorporation or injection of applied manure into the soil. Therefore, filtration and
adsorption of manure through soil contact is prevented. Both mechanisms are important for
attenuating microorganism losses (Gerba, D., C. Wallis, and J. Mellnick, 1975; Patni, N.K., H.R.
Toxopeus, and P.Y. Jui, 1985).
There are several additional disadvantages to winter manure application. Runoff
from winter-spread fields during winter thaws or spring snowmelt occurs before the growing
season. Riparian buffers or vegetated filter strips are relatively inactive at this time and therefore
8-8
-------
ineffective in removing pollutants from runoff before delivery to surface waters. Also, winter
application may occur due to lack of adequate manure storage. Since the manure must be applied
frequently, a loss of management flexibility occurs which makes good nutrient management
difficult.
Although several studies have reported little water quality impact from winter-
spread manure (Klausner, S.D., P.J. Zwerman, and D.F. Ellis, 1976; Young, R.A. and R.F. Holt,
1977; Young,.R.A. and C.K. Mutchler, 1976), such findings typically result from fortuitous
circumstances of weather, soil properties, and timing/position of manure in the snowpack._ The
spatial and temporal variability and unpredictability of such factors makes the possibility of ideal
conditions both unlikely and impossible to predict. .
8.6
References
Brown, M.P., P. Longabucco, M.R. Rafferty, P.D. Robillard, M.F. Walter, and D.A. Haith, 1989.
Effects of animal waste control practices on nonpoint-source phosphorus loading in the
West Branch of the Delaware River watershed. J. Soil and Water Conserv. 44(1):67-70.
Carrington, E.G. and M.E. Ransome, 1994. Factors influencing the survival of Cryptosporidium
oocysts in the environment Report No. FR 0456. Foundations for Water Research.
Marlow, Bucks.
Clausen, J.C., 1990. Winter and Fall application of manure to corn land. Pages 179 - 180 in
Meals,-D.W. 1990. LaPlatte River Watershed Water Quality Monitoring and Analysis
Program: Comprehensive Final Report. Program Report No. 12. Vermont Water
Resource Research Center, University of Vermont, Burlington.
Clausen, J.C., 1991. Best manure management effectiveness. Pages 193 - 197 in Vermont RCWP
Coordinating Committee. 1991. St. Albans Bay Rural Clean Water Program, Final Report.
Vermont Water Resources Research Center, University of Vermont, Burlington
Clausen, J.C. and D.W. Meals, 1989. Water quality achievable with agricultural best management
practices. J. Soil and Water Conserv. 44(6):593-596.
Converse, J.C., G.D. Bubenzer, and W.H. Paulson, 1976. Nutrient losses in surface runoff from
winter spread manure. Trans. ASAE 19:517-519.
8-9
-------
Payer, R. and T. Nerad, 1996. Effects of low temperature on viability of Cryptosporidium parvum
oocysts. Appl. and Environ. Microbiol. 62(4):1431-1433
Gerba, D., C. Wallis, and J. Mellnick, 1975. Fate of wastewater bacteria and viruses in soil. J. Irr.
Drain. Div. ASCE 101:157-174.
Hensler, R.F., R.J. Olsen, S.A. Witzel, OJ. Attoe, W.H. Paulson, and R.F. Johannes, 1970. Effect
of method of manure handling on crop yields, nutrient recovery, and runoff losses. Trans
ASAE 13(6):726-731.
. , ,-• r •* •'
Kibby, H.J., C. Hagedorn, and E.L. McCoy, 1978. Use of Fecal Streptococci as indicators of
pollution in soil. Appl. and Environ. Microbiol. 35(4):711-717.
Klausner, S.D., P.J. Zwerman, and D.F. Ellis, 1976. Nitrogen and phosphorus losses from winter
disposal of dairy manure. J. Environ. Qual. 5(l):47-49.
Kudva, I.T., K. Blanch, and CJ. Hovde, 1998. Analysis of Escherichia coli O157:H7 in ovine or
bovine manure and manure slurry. Appl. and Environ. Microbiol. 64(9):3166-3174.
Melvin, S. and J. Lorimor, 1996. Effects of whiter manure spreading on surface water quality.
1996 Research Report, Agricultural & Biosystems Engineering, Iowa State University
Extension, Ames, IA. (http://www.nppc.org/Research/796Reports/796Melvin-
manure.html)
Midgeley, A.R. and D.E. Dunklee, 1945. Fertility runoff losses from manure spread during the
whiter. Univ. of Vermont, Agric. Exp. Station, Bulletin 523, 19 p.
Moore, I.C. and F.W. Madison, 1985. Description and application of an animal waste phosphorus
loading model. J. Environ. Qual. 14(3):364-368.
Patni, N.K., H.R. Toxopeus, and P.Y. Jui, 1985. Bacterial quality of runoff from manured and
non-manured cropland. Trans. ASAE 28Q: 1871-1884.
Phillips, P.A., A.J. MacLean, F.R. Hore, F.J. Sowden, A.D. Tenant, and N.K. Patni, 1975. Soil
water and crop effects of selected rates and times of dairy cattle liquid manure applications
under continuous corn. Engineering Research Service Contribution No. 540. Agriculture
Canada, Ottawa, Ontario.
Reddy, K.R., R. Khaleel, and M.R. Overcash, 1981. Behavior and transport of microbial
pathogens and indicator organisms hi soils treated with organic wastes. J. Environ. Qual.
10(3):255-266.
Steenhuis, T.S., G.D. Bubenzer, and J.S. Converse, 1979. Ammonia volatilization of whiter
spread manure. Trans. ASAE 22: 153-157.
8-10
-------
Stoddard et al. 1998.
Thompson, D.B., T.L. Loudon, and J.B. Gerrish, 1979. Animal manure movement in winter
runoff for different surface conditions. Pages 145-157 in R.C. Loehr et al., eds. Best
Management Practices for Silviculture and Agriculture. Ann Arbor Science, Ann .Arbor
.MI., ... , ' , , "V "-' ,.
Vansteelant, JY., 2000. Personal communication, Institut National de la Recherche Agronimique,
Thonon les Bains, France.
Young, R.A. and R.F. Holt, 1977. Winter-applied manure: effects on annual runoff, erosion, and
nutrient movement. J. Soil and Water Conserv. 32(5):219-222.
Young, R.A. and C.K.: Mutchler, 1976. Pollution potential of manure spread on frozen ground. J.
Environ. Qual. 5(2): 174-179.
8-11
-------
-------
Appendix A
-------
-------
Table A-l
Costs for Earthen Settling Basins at Beef Feedlots and Heifer Operations
Animal - •>
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Farm, Type
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef i -
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers -
„ , Region
Central
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
•Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific '
Pacific
Pacific
Pacific
South
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Size Class
Large 1
Large 2
Medium 1
Medium 2
Mediums
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3 •
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Capital
$1,084
$12,155
$413
$496
$591
$2,947
$38,378
$785
$1,054
$1,369
$2,780
$35,992.,
$751
$1,001
$1,297
$2,101
$26,457
$614
$800
$1,016
$4,471
$59,829
$1,092
$1,509
$2,002
$887
$413
$512
$618
$2,309 .
$792
$1,103
~*^ Annual
$54
$608
$21
$25
$30
, $147
$1,919
$39
$53
$68
. $139
$1,800
$38
$50
$65
$105
$1,323
- .$31.
$40
$51
$224
$2,991
$55
$75
$100
$44
$21
$26
$31
$115
$40
$55
A-l
-------
Table A-l (Continued)
Animal
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Farm Type ::
Heifers'
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Region
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Size Glass
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
•-;-,Y .Capital ..-..;•.
$1,449
$2,181
$758
$1,046
$1,373
$1,665
$622
$834
$1,069
$3,474
$1,103
$1,589
$2,127
.-•,. •.•••/Annual...; v :
$72
$109
$38
$52
$69
$83
$31
$42
$53'
$174
$55
$79
$106
A-2
-------
table A-2
Costs for Concrete Separators for Dairies and Veal Operations
"y':i,, Animal
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
,JFarm Type
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Region
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific .
Pacific
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Size Class
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Capital
$130,713
$28,880
$44,963
$60,458
$130,713
$28,880
$44,963
$60,458
$130,713
$28,880
$44,963
$60,458
$130,713
$28,880
$44,963
$60,458
$130,713
$28,880 .
$44,963
$60,458
$5,582
$3,605
$4,115
$4,601
$5,582
$3,605
$4,115
$4,601
$5,582
$3,605
$4,115
$4,601
Annual
$2,614
$578
$899
$1,209
$2,614
$578
$899
$1,209
$2,614
$578
$899
$1,209
$2,614
$578
$899
$1,209
$2,614
$578
$899
$1,209
$112
$72
$82
$92
$112
$72
$82
$92
$112
$72
$82
$92
A-3
-------
Table A-2 (Continued)
Animal
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Farm Type
Hose
Hose
Hose
Hose
Hose . ,
Hose
Hose
Hose
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Region
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
South
South
South
Size Class
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Capital
$5,582
$3,605
$4,115
$4,601
$5,582
$3,605
$4,115
$4,601
$42,711
$55,192
$101,511
$42,711
$55,192
$101,511
$42,711
$55,192
$101,511
$42,711
$55,192
$101,511
$42,711
$55,192
$101,511
Annual
$112
$72
$82
$92
$112
$72
$82
$92
$854
$1,104
$2,030
$854
$1,104
$2,030
$854
$1,104
$2,030
$854
$1,104
$2,030
$854
$1,104
$2,030
A-4
-------
r Table A-3a
Costs for Berms at Dairies, Beef Feedlots, Heifer and Veal Operations
HH^Ailimal
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef ;
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef..
Beef
Beef
Beef
Beef
Beef
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Farm .Type
Beef
Beef
Beef
Beef
Beef
Beef • ~
Beef
Beef
Beef .
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Flush
Flush
Flush
Flush
Flush
Flush
Flush
:^====
Region
Central
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
Pacific
South
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
~g*^—
Size Class
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Capital
$5,187
$19,466
$2,327
$2,842
$3,348
~ $5,187
$19,466
$2,327
$2,842
$3,348
$5,187
$19,466
$2,327
$2,842
$3,348
$5,187
$19,466
$2,327
$2,842
$3,348
$5,187
$19,466
$2,327
$2,842
$3,348
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
~ 'Annual j
$104 I
$389
$47
$57
$67
$104
$389
$47
$57
$67
$104
$389
$47
$57
$67
$104
$389
$47
$57
$67
$104
$389 •
$47
$57
$67
$61
$26
$33
$40
$61
$26
$33
A-5
-------
Table A-3a (Continued)
Animal
Dairy
Dairy -
Dairy
Dairy
Dairy
3airy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Heifers
Farm Type
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose.
Hose
Hose
Hose
Hose
Hose
Heifers
Region
Mid-Atlantic
Midwest
Midwest
Vlidwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Size Class >:
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
.Capital
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
. $1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$3,069
$1,283
$1,673
$1,988
$4,536
Annual |
$40 1
*~.$l6i
$26
$33
$40
$61
$26
$33
$40
$61
$26
$33
$40
$61
• $26
$33
$40
$61
$26
$33
$40
$61
$26
$33
$40
$61
$26
$33
$40
$61
$26
$33
$40
$91
A-6
-------
TaTble A^la (Continued)
;;;?'.,'-;?Aiiimal . .
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
leifers
Heifers
leifers
Farm Type
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Region
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Size Class
Medium 1
Medium 2
Medium 3,
Large 1
Medium 1
Medium 2
Mediums ,
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Capital
$2,342
$2,928
$3,465
$4,536
$2,342
$2,928
$3,465
$4,536
$2,342
$2,928
$3,465
$4,536
$2,342
$2,928
$3,465
$4,536
$2,342
$2,928
$3,465
Annual
-$47
$59
$69
$91
$47
$59
$69
$91
$47
$59
$69
$91
$47
$59
$69
' $91
$47
$59
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-------
Table A-il
Costs for Supplemental Commercial Nitrogen
at Dairies, Beef Feedlots, Veal and Heifer Operations
P-Based Scenario
;? gSAnimal
Beef
Beef
Beef ••-
Beef
Beef
Beef
Beef
Beef
Beef 3
Beef - -
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
)airy
Dairy
Dairy
Dairy
Farm Type
Beef
Beef
Beef
Beef
Beef
Beef . ' ._
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Flush
Flush
Flush
Flush
- Region
Central
Central
Central
Central
.Central
Mid- Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
Pacific
South
South
South
South
South
Central
Central
Central
Central
Size Class
Large 1
Large 2
Medium 1
Medium. 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Category 1
Annual Costs
$28,320
• $398,808
$5,698
, $8,501
$11,796
$35,337
$497,622
$7,110
$10,607
$14,719
$36,697
$516,770
$7,383
$11,015
$15,285
$40,991
$577,240
$8,247
$12,304
$17,074
$10,322
$145,356
$2,077
$3,098
$4,299
$25,361
$4,434
$7,537
$10,641
Category 2
Annual Costs
$12,131
$166,261
$3,446
$7,450
$12,158
$12,382
$168,227
$3,843
$8,839
$14,714
$12,859
$174,700
$3,991
$9,179
$15,280
$18,523
$254,388
$5,147
$10,943
$17,757
$3,617
$49,139
$1,123
$2,582
$4,298
$7,300
$5,248
$3,254
$7,673
A-81
-------
Table A-ll (Continued)
A-82
-------
Table A-ll (Continued)
Animal
Dairy
Dairy
Dairy
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Farm Type
Hose
Hose
Hose
Heifers
Heifers
Heifers -
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Flush
Flush
Flush
Flush
Flush
Flush ;
Flush
Flush '
Flush
Flush
Region
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Pacific
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1 '
Medium 1
Medium 2-
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium3
Medium 1
Category 1
Annual Costs
$1,077
$1,831
$2,585
$6,243
$1,665
$2,601
$3,642
$7,881
$2,102
. $3,284
$4,597
$7,881
$2,102
$3,284
$4,597
$9,081
$2,422
$3,784
$5,297
$2,224
$593
$927
$1,297
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
Category 2
Annual Costs
$1,212
$356 .
$1,428
$7,639
$1,099
$2,437
$3,923
$9,518
$1,261
$2,950
$4,827
$9,518
$1,261
$2,950
$4,827
$11,156
$1,642
$3,588
$5,750
$2,686
$356
$833
$1,362
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
A-83
-------
Table A-ll (Continued)
Animal
Veal
Veal
Veal
Veal
Veal
Farm Type «
Flush
Flush
Flush
Flush - -
Flush
Region: •,..'.;
Pacific
Pacific
South
South
South
V>Size_Glass:. ••_-;
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
;;^Ca)l:egwy>l.;^
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$0 ;
$0
$0
$0
$0
v ^Category- 2; ^:
Annual Coists
'SO
$0
$0
$0
$0
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A-98
-------
Table A-14
Costs for Concrete Pads for Beef, Dairy, Heifer, and Veal Operations
Animal
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
>;:?Farm|I^pfe;: ~
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef ,.
Beef
Beef
Beef
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Region
Central
Central
Central
Central
Central
Mid-Atlantic .
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
Pacific
South
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Size Oaf s
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
MediumS
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
MediumS
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Capital
$134,541
$1,730,701
$31,232
$44,504
$59,816
$132,317
$1,700,762
$30,751
$43,803
$58,859
$133,861
$1,721,541
$31,085
$44,290
$59,523
$132,058
$1,697,279
$30,695
$43,722
$58,747
$131,707
$1,692,566
$30,620
$43,611
$58,596
$93,642
$21,276
$32,762
$43,796
$93,642
$21,276
$32,762
$43,796
Annual
$2,691
$34,614
$625
$890
$1,196
$2,646
$34,015
$615
$876
$1,177
$2,677
$34,431
$622
$886
$1,190
$2,641
$33,946
$614
$874
$1,175
$2,634
$33,851
$612
$872
$1,172
$1,873
$426
$655
$876
$1,873
$426
$655
$876
A-99
-------
Table A-14 (Continued)
Animal
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Heifers
Heifers
Heifers
Heifers
Farm Type
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose .
Hose
Hose
Hose
Hose"
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Heifers
Heifers
Heifers
Heifers
^Region
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South .
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Central
SizeClass?
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Capital;
$93,642
$21,276
$32,762
$43,796
$93,642
$21,276
$32,762
$43,796
$93,642
$21,276
$32,762
$43,796
$42,615
$10,723
$15,933
$20,855
$42,615
$10,723
$15,933
$20,855
$42,615
$10,723
$15,933
$20,855
$42,615
$10,723
$15,933
$20,855
$42,615
$10,723
$15,933
$20,855
$651
$570
$591
$611
•/.;-•„.• .Animal !•.'..'.*':
$1,873
$426
$655
$876
$1,873
$426
$655 '
$876
$1,873
$426
$655
$876
$852
$214
$319
$417
$852
$214
$319
$417
$852
$214
$319
$417
$852
$214
$31.9
$417
$852
$214
$319
$417
$13
$11
$12
$12
A-100
-------
Table A-14 (Continued)
< ; Animal
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers -
Heifers
Heifers
Heifers
Heifers
Heifers "
Heifers
Heifers
Heifers
Heifers .
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Veal
Farm Type _ '
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
< Region
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
South
South
South
Size Class
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Medium 1
Medium 2
Medium 3
Capital
$797
$639
$679
$718
$704
$595
$623
$650
$811
$645
$687
$727
$828
$653
$698
$740
$2,276
$2,689
$4,117
$2,276
$2,689
$4,117
$2,276
$2,689
$4,117
$2,276
$2,689
$4,117
$2,276
$2,689
$4,117
Annual
$16
$13
$14
$14
$14
$12
$12
$13
$16
$13
$14
$15
$17
$13
$14
$15
$46
$54
$82
$46
$54
$82
$46
$54
$82
$46
$54
$82
$46
$54
$82
A-101
-------
Table A-15
Costs for Composting at Dairies, Beef, and Heifer Operations
Animal
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Daiiy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Farm Type
Beef
Beef
Beef
Beef .
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Region
Central
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
Pacific
South
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
;.; Size Class
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
MediumS
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
.';:. Capital ?
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157 ;
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157 ;
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157 :
$9,157
$9,157
$9,157
•-/ ";;Aiinual:,v -,.,:
$67,803
$954,694
$13,653
$20,356
$28,251
$58,841
$828,603
$11,839
$17,662
$24,509
$60,390
$850,412
$12,167
$18,127
$25,167
$58,860
$828,877
$11,842
$17,668
$24,517
$58,784
$827,804
$11,827
$17,645
$24,485
$7,995
$1,413
$2,380
$3,365
$4,261
$744
$1,265
A-102
-------
Table A-15 (Continued)
Animal
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Heifers
Farm Type
Flush ;
Flush- •!;.
Flush
Flush '
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Hose •
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Heifers
Region
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific'
Pacific
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific ,
South
South
South
South
Central
Size Class
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large!
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Capital
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
. $9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157
" Annual
$1,786
$7,196
$1,264
$2,138
$3,031
$2,867
$503
$856
$1,210
$1,567
$280
$466
$653
$7,995
$1,413
$2,380
$3,365
$4,261
$744
$1,265
$1,786'
$7,196
$1,264
$2,138
$3,031
$2,867
$503
$856
$1,210
$1,567
$280
$466
$653
$26,997
A-103
-------
Table A-15 (Continued)
Animal
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Farmltype, v
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers • —
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
.Region : ,<
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest -•
-Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
- .Size Class,
Medium 1
Medium 2
Medium 3
Large 1
Medium 1 ,
Medium 2 ,
Medium 3
Large 1
Medium 1
Medium 2
'Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
•;',: /'Capital ':•-,/':
$9,157
$9,157
$9,157
$9,157 ;
$9,157
. , $9,157
$9,157
$9,157
$9,157 ,
$9,157 ;
•$9,157
$9,157 |
$9,157
$9,157
$9,157
$9,157
$9,157
$9,157 i
$9,157
'•• • -Annual;' ''• .,'
$7,209
$11,260
$15,756
$19,064
$5,091
$7,952
.$11,111
$22,780
- $6,076
$9,495
$13,285
$19,4-73
$5,203
$8,120
$11,371
$16,537
$4,422
$6,894
$9,662
A-104
-------
Table A-16
Costs for Digesters for Large Dairies for all Regions
IV Animal
Dairy
Dairy
Farm Type
Hose '
Flush
Size .Class
Large 1
Large 1
Digester Type
Complete Mix
Covered Lagoon
Capital
$377,447
$214,353
O&M
($45,560)
($42,062)
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A-115
-------
Table A-18
Costs for Covered Lagoons at Veal Operations Under Option 5
Animal
Veal
Veal
Veal
Veal
Veal •
Veal
Veal
Veal
Veal.
Veal ;
Veal
Veal
Veal
Veal
Veal
Farm Type
Flush
Flush
Flush
Flush
Flush :
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Region v
Central
Mid-Atlantic
Midwest
Pacific
South
Central
Mid-Atlantic
Midwest
Pacific
South i
Central
Mid-Atlantic
Midwest
Pacific
South
^v:/Si?e Class- c,;
Medium 1
Medium 1
Medium 1
Medium 1
Medium 1
Medium 2
Medium 2
Medium 2
Medium 2
Medium 2
Medium 3
Medium 3
Medium 3
Medium 3
Medium 3
-',; Capital ;.•:•',,•::
$65,959
$79,984
$75,264
$79,366
$68,049
$77,377
$89,261
$83,167
$93,320
$89,588
$100,765
$114,140
$107,803
$118,625
$114,198
Annual , :
$3,298
$3,999
$3,763
$3,968
$3,402
$3,869
$4,463
$4,158
$4,666
$4,479
$5,038
$5,707
$5,390
$5,931
$5,710
A-116
-------
Table A-19
Costs for Sludge Removal at Dairies, Beef Feedlots, and Heifer Operations
;£• Animal ".".;"
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef , j i
Beef .
Beef
Beef . • ., _„,
Beef
Beef
Beef .
Beef
Beef <
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Beef
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
:•',. ••Faimi.Iypfc v '•
Beef !
Beef
Beef
Beef
Beef
Beef
Beef '
Beef
'Beef.-.
Beef
'Beef .
iBeef ;,
Beef
Beef
Beef
Beef
Beef
Beef,
Beef
Beef :
Beef ;
Beef '
Beef
Beef
Beef .
Flush
Flush
Flush . .
Flush
Flush
Flush
Flush:
•'••''-•;•: ^Region
Central
Central
Central
Central
Central" •
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic :
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
Pacific
South' .. '.-..-
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Size Class
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2 :
Medium 1
Medium 2 ",
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Large 2
"Medium 1
Medium 2
Medium 3
Large 1
Large 2
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Capital -
$0
$122,426
$0
$0
$0
$0
$122,426
$0
$0
$0
$0
$122,426 .
$0
$0
$0 -
$0
$122,426
$0
$0
$0
$0
$122,426
$0
$0
$0
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
Annual
$2,377
$6,121
$478
$714
$990
$7,693
$6,121
$1,548
- $2,309
$3,204
$4,004
$6,121
$806
$1,202
$1,668
$8,312
$6,121
$1,672
$2,495
$3,462
$9,148
$6,121
$1,841
$2,746
$3,811
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
A-117
-------
Table A-19 (Continued)
Animal
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Dairy
Heifers
Farm Type
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Flush
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Hose
Heifers
Region
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Central
" ' Size Class .;/:
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2 •
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
•;, Capital ,..;
$122,426
.$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$122,426
$0
$0
$0
$122,426
$0
$0
$122,426
$122,426
•$o
$0
$122,426
$122,426
$0
$122,426
$122,426
$122,426
$0
$122,426
$122,426
$0
- •:•':• .-Ajinual" ;';',,' ;
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$6,121
$9,711
$16,509
$23,307
$6,121
$13,614
$23,144
$6,121
$6,121
$10,906
$18,539
$6,121
$6,121
$14,068
$6,121
$6,121
$6,121
$14,682
$6,121
$6,121
$1,818
A-118
-------
Table A-19 (Continued)
;-;.i!; ;^£niinal-!v-
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers : -
Heifers
Heifers
Heifers
ieifers
leifers
leifers
ieifers
.«iFara'Type-;r';
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
Heifers
•: ;•:••;' Region
Central
Central
Central
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Mid-Atlantic
Midwest
Midwest
Midwest
Midwest
Pacific
Pacific
Pacific
Pacific
South
South
South
South
Size Class
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Large 1
Medium 1
Medium 2
Medium 3
Capital
$0
$0
$0 ,
$0
$0
$0
$0
$0
$0
$0
$0 .
$0
$0
$0
$0
$0
$0
$0
$0
Annual
$485
$757
$1,060
$5,883
$1,569
$2,451
$3,432
$3,062
$816
$1,276
$1,786
$6,356
$1,695
$2,648
$3,708
$6,996
$1,865
$2,915
$4,081
A-119
-------
-------
Appendix B
-------
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Appendix C
-------
-------
Table C-la
Summary of Industry Costs for Option 1
Animal
:£•$$••',
Beef
Dairy
Dairy •:
Heifers
Veal
Chicken
Chicken
Chicken
Swine
Swine
Swine
Swine
Swine
Swine
Turkey
Manure Type
Solid/Liquid
Solid/Liquid
Solid/Liquid
Solid/Liquid
Liquid
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Solid
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Liquid
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Type; /
Beef - -
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Hose
Heifers
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,LW
BR
LA
FF
GF
FF
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GF
SL
Capital
$66,271,376
$262,639,714
$33,153,994
$13,452,388
$0
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$93,407,347
$32,664,307
$108,469
$111,079
$5,308,843
$4,017,456
$360,663
$334,852
$31,170,087
Annual
$8,689,062
$45,358,315;
$4,072,126
$1,319,976
$30,553
$1,296,980
$4,060,985
$1,746,196
$150,883
$154,573
$1,686,581
$1,135,603
$1,497,912
$1,720,540
$1,668,463
Tixed
$4,305,153
$2,626,098
$2,461,447
$694,719
$38,948
$132,432
$2,184,684
$356,844
$84,495
$86,411
$844,688
$527,369
$889,058
$957,771
$701,880
3-Year
Recurring
- ,$592,050
$183,113
$2,798,726
$204,401
$2,422
$19,525
$74,888
$51,695
$3,970
$4,054
$30,149
$22,505
$30,374
$38,814
$27,143
5-Year
Recurring
$2,530,516
$894,258
$739,387
. $82,858
$10,090
$81,264
$1,009,264
$247,758
$35,289
$36,036
$241,083
$171,891
$272,588
$329,614
$450,698
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Table C-2a
Summary of Industry Costs for Option 2
Animal
TType
Beef
Dairy
Dairy
Heifers
Veal
Chicken
Chicken
Chicken
Swine
Swine
Swine
Swine
Swine
Swine
Turkey
«. Manure
Type
Solid/Liquid
Solid/Liquid
Solid/Liquid
.Solid/Liquid
Liquid
Liquid
Solid
Solid
Evapor
Evapor
Liquid
Liquid
Pit
Pit
Solid
Operation
Type
Beef
Flush
Hose
Heifers
Flush
LW
BR
LA
FF
GF
FF
GF
FF
GF
SL
i* 4
Capital"
$96,942,128
$147,690,591
$35,758,320
$16,559,995
$0
$.14,047,475
$93,515,959
$32,642,246
$109,151
$112,054
$6,645,012
$4,934,234
$505,620
$454,228
$31,276,907
Annual
$38,651,376
$115,353,998
$8,280,186
$2,305,508
$30,553
$1,491,472
$4,120,237
$1,929,765
$151,249
$155,285
$1,803,879
$1,196,853
$13,907,671
$19,817,425
$2,864,728
- Fixed
$7,672,585
$3,188,393
$3,066,584
$842,928
$38,948
$144,601
-$2,303,023
$333,911
$128,484
$131,852
$1,358,438
$855,210
$1,398,631
$1,538,482
$835,304
3-Year
Recurring
$1,496,851
$334,556
$2,961,250
$243,437
$2,422
$22,435
$83,562
$47j230
$8,945
$9,178
$86,947
$61,344
$82,198
$101,262
$35,254
• 5-Year !
Recurring
$9,179,452
$2,017,898
$1,916,937
$312,186
$10,090
$93,337
$1,127,487
$224,575
$79,289
$81,337
$6,894,239
$5,231,336
$781,926
$910,429
$584,319
C-35
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table C-3a
Summary of Industry Costs for Option 5
Animal Type
Chicken
Chicken
Chicken - -•
Swine
Swine,
Swine
Swine
Swine
Swine
Turkey
Veal
Manure
Type
Liquid
Solid
Solid
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Pit
Solid
Liquid
Operation
Type
LW
BR
LA "
FF
GF
FF
GF
FF
GF
SL
Flush "
-Capital
$22,224,957-
$184,992,580
$32,642,246
$43,483,000
$44,603,942
$341,161,677
$250,152,138
$37,452,731
$46,434,556
$31,276,907
$1,036,004.
Annual
$1,711,084
$4,120,237
$1,929,765
$1,830,320
$1,877,631'
$10,805,902
$7,850,690
$12,278,113
$18,034,408
$2,864,728
. $82,351
Fixed
$200,193
$2,303,023
$333,911
$138,485
$142,109
$1,458,059
$920,791
$1,398,631
$1,538,482
$835,304
$38,948
„ 3-Year
Recurring
$35,781
$83,562
$47,230
$10,060
$10,321
$98,623
» -,$69,564
$82,198
$101,262
$35,254
$2,422
5-Year,
Recurring
$148,929
$1,127,487
$224,575
$89,300
$91,605
$838,708
- $552,835
$781,926
-$910,429
-$584,319
$10,090
C-97
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