Nutrient Recovery: Evaporation Technologies
alternative practice names:
Varcor© Sedron®
Evaporation technologies use heat to concentrate liquid manure to reduce volume. Evaporative systems typically use multi-stage thermal and/or electrical inputs under vacuum to distill and then condense "clean water" from manure liquids while concentrating most of the nutrients in the residual manure solids. Compounds are released (e.g., ammonia, hydrogen sulfide) as the water is driven off, and this often requires additional treatment such as condensation of the water and/or scrubbing of the chemicals.
The resulting concentrated manure solids can be sold as fertilizer or used on farms reducing storage, handling, and application requirements compared to standard manure. Evaporation technologies are commercially available in Europe and are currently being tested at scale in the U.S.
When used, in what regions in the U.S. is the practice found:
Northwest, Upper Midwest, Southwest, West
FARM SIZE
When used, typically found on farms of the following sizes:
Over 5000 cows

Practice Benefits
Enables operation expansion: By transforming waste into valuable resources, the system allows farmers to manage waste more efficiently, which can support farm expansion without the need for additional land or resources for waste management.
Increases profitability: By converting waste into marketable products such as fertilizers and clean water, the system creates additional revenue streams. This can significantly enhance the profitability of farming operations.
Reduces maintenance requirements: The system eliminates the need to maintain liquid manure storage system waste and reduces the risk of environmental contamination, leading to lower maintenance and compliance costs.
Diversifies income: By producing sellable commodities like fertilizers, the system provides farmers with opportunities to diversify their income sources beyond traditional agricultural products.

Implementation Insights
Site-specific or Farm-specific requirements

Manure collection methods: This practice is well-suited for farms using a free-stall/cross-vent barn, which collects manure using a scrape/vacuum process, a fiber separator, and an anaerobic digester.
Required Capital Expenditures (CapEx)

Evaporative system equipment: The primary capital expenditure is the system itself, which includes the mechanical vapor recompression unit and associated components necessary for processing liquid waste into valuable outputs like clean water and fertilizers.
Engineering plans: Custom engineering may be required to integrate the system with existing farm infrastructure. This includes designing interfaces and ensuring compatibility with current operations.
Buildings: Depending on the farm's existing facilities, new buildings or modifications to existing structures may be needed to house the system and protect it from environmental elements.
Infrastructure upgrades: These upgrades may include the installation of pumps and piping systems to transport waste to the unit and distribute processed water and fertilizers, water holding tanks to store clean water produced by the system for irrigation or livestock use, and modified power supply (e.g., three-phase power source and additional amperage capacity) to support the energy requirements of the system.
Required Operational Expenditures (OpEx)

Labor: Operating the system may require hiring additional personnel or training existing staff to manage and maintain the equipment effectively. Skilled operators are essential to ensure the system functions optimally and to handle any technical issues that may arise.
Supplies: While the system does not require chemical additives for its core processes, there may be occasional needs for supplies related to system maintenance or ancillary processes.
Maintenance: The system, like any complex machinery, requires regular maintenance to ensure it operates efficiently and to prevent downtime. This includes routine inspections, cleaning, and servicing of components.
Parts replacement: Some parts of the system may experience wear and tear over time and will need to be replaced periodically. This could include components like filters, seals, or other mechanical parts integral to the system's operation.
Electricity: The system relies on mechanical vapor recompression, which requires a significant amount of energy. Therefore, electricity costs are a recurring expense, and farmers need to account for the increased energy consumption associated with running the system.
Implementation Considerations

Training: Farmers will need to train personnel to operate and maintain the system, which involves understanding the mechanical vapor recompression process and managing the equipment effectively. However, some may not have the necessary skills to operate the system independently and might need to rely on outside contractors or establish agreements with specialized service providers to manage and run the facility effectively.
Integration with existing operations: The system must be integrated into the farm's existing waste management practices, which may require adjustments to current workflows and processes. Regular System Repairs and Maintenance: The system requires regular maintenance to ensure optimal performance. This includes routine inspections, cleaning, and servicing of mechanical components to prevent downtime and extend the system's lifespan.
Initial setup and integration: Farmers may encounter challenges during the initial setup and integration of the system with existing infrastructure, especially if modifications are needed.
Energy consumption: The system's reliance on electricity for mechanical vapor recompression can lead to increased energy costs, which may be a concern for some farmers.
Technical expertise: The complexity of the system may necessitate hiring or training skilled personnel, which can be a barrier for farms with limited access to technical expertise.
Financial Considerations and Revenue Streams
There are no federal cost-share programs or conservation funding for this practice.
Additional Resources
► See the Newtrient Solutions Catalog to learn more about Evaporative Technologies and related solution providers.
Manual: Approaches to Nutrient Recovery from Dairy Manure (Washington State University)

Environmental Impacts
MAY REDUCE FARM GREENHOUSE FOOTPRINT
Although detailed research quantifying the impact of nutrient recovery on farm greenhouse gas (GHG) emissions is limited, models indicate that evaporation technologies can reduce farm GHG emissions. In addition, some evaporative systems can further contribute to reducing the carbon footprint of dairy operations by displacing the need for chemical fertilizers and lowering methane emissions from traditional manure storage systems.
IMPROVES WATER QUALITY
These systems significantly reduce the volume of liquid waste by using heat to evaporate water from manure. Additionally, evaporative systems can aid in nutrient management. By concentrating nutrients like phosphorus and nitrogen in the remaining solids, farmers can more effectively control nutrient application in fields, reducing the risk of nutrient runoff in water bodies.
REFerences

Alignment with FARM Program
This practice is not included in the FARM program.
Contents
We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights.
We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights.
Evaporation technologies use heat to concentrate liquid manure to reduce volume. Evaporative systems typically use multi-stage thermal and/or electrical inputs under vacuum to distill and then condense "clean water" from manure liquids while concentrating most of the nutrients in the residual manure solids. Compounds are released (e.g., ammonia, hydrogen sulfide) as the water is driven off, and this often requires additional treatment such as condensation of the water and/or scrubbing of the chemicals.
The resulting concentrated manure solids can be sold as fertilizer or used on farms reducing storage, handling, and application requirements compared to standard manure. Evaporation technologies are commercially available in Europe and are currently being tested at scale in the U.S.
Practices and technologies
Nutrient Recovery: Evaporation Technologies
alternative practice name:
Varcor© Sedron®