Gale Gordon says there haven't been any problems with the anaerobic digester on their farm, which was designed by Steve Dvorak. 

By numerous accounts, the biogas system designed by Steve Dvorak, GHD Inc., Chilton, have worked according to design specifications, with no interruptions due to the biogas production system itself.
The disparity between publicity surrounding the various biogas systems and their performance have made it difficult for farmers to determine whether to invest in the systems and has fostered doubts about the government programs funding the development of these endeavors. 

A SOLID PERFORMER 

                Dvorak won't comment directly on other biogas systems that other firms have been installed on Wisconsin dairy farms. Dvorak says electrical production is the best gauge of a system's success, although a biogas system has other benefits, such as reducing odor and the ability to recycle bedding.

                " The better the degradation, the more methane produced and the more electricity. It's very simple," he says.

                His firm has installed four biogas systems in the state, three on diary farms and one on a poultry operation, in addition to having spent years working with a system installed at a slaughter plant. Several systems are planned for farms in other states.

                Dvorak, a professional engineer says simplicity is essential in biogas systems for on-farm use. He says a system designed for a municipal sewage plant isn't suitable for a farm. Farmers, he says, lack the time and resources necessary to periodically sample and test the waste stream and make adjustments, as required in a municipal treatments system.

                The system installed on the Double-S Dairy, Alto, has been operational since March. One installed on Holsum Diary, Hilbrook, handles waste from 2,600 cows and "produces more biogas than the engine can handle, " Dvorak says.

                The best way to gauge a system's performance is to talk to the farmer who has installed one, he says.

                There haven't been any problems with the system Dvorak installed on the Deere Ridge Diary Farm of Gale and Kyle Gordon, Nelsonville, Gale Gordon says. There have been some glitches, due to cooper sulfate used in footbaths, and a few problems with the generating equipment owned by Alliant Energy.

Gale Gordon says the system has steadily produced methane since February.

                "We felt we could work with Dvorak," Gale says. The Gordon's looked at several systems and were impressed with the reliability and simplicity of the system installed on the Haubenschild farm, Princeton, Minn. It was designed by RCM Inc., which installed the system on the Stencil Farm in Denmark, Wis.

                Gale Gordon says it will take about six years to recover the costs of the system. The utility owns and operates the generating system, which according to Bill Johnson with Alliant Energy, represents 40 to 50 % of the cost of it. (California electricity and gas are 2  to 3 times more expensive than Wisconsin's)

                Johnson says the Gordon's system has been very reliable. " A farmer should not invest in a digester solely to generate electricity, " he says. He recommends that farmers do the same by investing in a system that " has a history."

                Dvorak says biogas systems are generally most economical on farms with at least 300 to 400 cows, which requires an initial investment of about $ 500 per cow. With fewer cows, the investment can exceed $1,000 per cow.

4000 cow dairies cost approx $400.00 per cow
10000 cow dairies cost approx $300.00 per cow

                Anaerobic digestion technology is a powerful tool for managing organic farm waste, particularly cow, swine and chicken manure. In addition to reducing waste volume and odor, however, the process also yields energy in the form of methane, or biogas. Farms making use of this technology have been able to manage their volume of animal waste and produce part or all the energy their farm operation requires as well. While some argue that low fossil fuel prices have kept anaerobic digestion technologies from realizing their full potential as energy producers, the advents of strict new laws regulating odor, groundwater contamination, and greenhouse gases are making the process attractive for waste management compliance.