2.1 Study area and system description
This study was carried out in the third Yinxiang weiye international ranch, which located in Cao County, Heze City, Shandong Province (115 ° 32 ′ E, 34 ° 35 ′ N), which had the typical characteristics of large-scale dairy farm. In 2018, there were 5,037 cows in the pasture, and 36 barns were built, all of which were fully open free lying barns with playground. Large scale dairy cows caused a lot of fecal pollution. The total daily fecal pollution of dairy farm was about 200 t, including 125 t fresh feces, 60 t urine and 15 t production sewage. To deal with the daily fecal pollution, the farm had two sets of solid-liquid separation equipment, two sets of silo aerobic fermentation unit and eight forced ventilation static stacks. These deviced provided two scenarios for fecal regeneration systems.
Scenario A: Forced ventilation static stack aerobic fermentation (FVSSAF) system, the cow dung solid treated by aeration for a period was composted by ventilated static pile for about 12 days. Then it was turned and dried in the drying field of the pasture for 2 days and used as bedding for the cow bed.
Scenario B: Bedding recovery unit (BRU) system was developed by Austrian fan company, which equipped with solid-liquid separation host and fermentation bin. The separated fecal solids can be subjected to aerobic fermentation for 10–12 hours. At the same time, the high temperature in the fermentation bin can eliminate the bacteria that may cause cow mastitis and obtain clean cow bedding.
2.2 LCA analysis
The ISO 14040 guideline was followed to carry out the study (ISO, 2006). The LCA analysis of two fecal regeneration bedding systems produced by the two methods was divided into four parts: determination of target and scope, inventory analysis, impact evaluation and result interpretation.
2.2.1 Goal and scope
The system boundary of both systems was: starting from the transportation of dairy manure to the manure treatment area, and the ending with the treatment of dairy manure into bedding that can be discharged (Fig. 1). The functional unit (FU) for the evaluation was one of fresh dairy manure, and other auxiliary inputs (wood chips etc.), energy inputs (i.e. electricity and diesel), product output, and pollutant emissions were all based on the corresponding values per functional unit.
2.2.2 Life cycle inventory analysis
Life cycle inventory is a quantitative analysis of all material, energy and emissions within the system boundaries of its research system for products, processes or activities, usually in the form of a data inventory table (Hélias et al., 2020). The basic data of daily operation consumption of two kinds of cushion material regeneration scenarios in this study are mainly through field investigation. GHGs emission data are from experimental detection, and the remaining data such as public system reference data are from public literature.
Scenario A:
There are eight forced ventilation static stacks in the pasture, each static stack can deal with 19 m3 cow dung. The static stack is equipped with 4 roots fans of 5kW power, and the fan ventilation time is set to 8 minutes on and 10 minutes off. After 12 days of forced aerobic fermentation, the dairy manure was piled up and dried for 2 days, and the ranch was equipped with a 10,000 cubic meter drying site. The drying is done by turning with a rake three times a day, consuming 13 liters of diesel fuel each time. At this point, the moisture of cow manure can be reduced to less than 50% and can be used as bedding for cows. The environmental emissions of forced ventilation static stack regeneration bedding system mainly include greenhouse gas emissions during composting, fan energy consumption, solid-liquid separator energy consumption and greenhouse gas emissions during drying.
The emission rates of CO2, CH4 and N2O in the composting process of the system were 441.25 mg·kg− 1·h− 1, 1.35 mg·kg− 1·h− 1 and 94.41 µg·kg− 1·h− 1, respectively. The emission coefficients of greenhouse gases in the drying process were shown in the research results (Ba et al., 2020). Four different stages were selected for the experiment. After weighted average, the emission rates of greenhouse gases CO2, CH4 and NO2 in the fermentation process were determined as 29.88 mg·kg− 1·h− 1, 0.77 mg·kg− 1·h− 1 and 37.47 µg·kg− 1·h− 1, respectively. The emission coefficient of NH3 in the composting process was determined as the method of Ba et al. (2020).
The total energy consumption of solid-liquid separation process in one day was 620 kWh, and 40 m3 solid cow dung was obtained, namely 15.5 kWh· FU − 1. The total energy consumption of the fan during composting was 2560 kWh, that is, 20 kWh· FU− 1, and the energy consumption of the treatment process was mainly electric power consumption.
Given the boundary of the evaluation system, that is, the manure is transported to the treatment area until the cow manure is fermented and dried to become the cow bed bedding product, the treatment stage is only considered.
Scenario B:
The rated feed flow rate of the silo fermentation system was 45 m3/ d. The emission rates of CO2, CH4 and N2O during the operation of BRU were 3574.4 ± 337. 2mg·s− 1, 3.88 ± 0.93 mg. s− 1 and 0.052 ± 0.012 mg. s− 1, respectively. CO2 emission was 3.30 ± 0.32 kg·FU− 1, CH4 emission was 3.60 ± 1.77 g·FU− 1, N2O emission was 47.53 ± 89.66 mg·FU− 1.
The total power of BRU was 29 kW, and 40 m3 cushion can be produced in 20 hours. The energy consumption of aerobic fermentation process was 580 kWh, that is, the unit energy consumption of functional evaluation was 12.89 kWh·FU− 1.
The pollutant emissions of the two treatment scenarios of FVSSAF system and BRU system were summarized, and the list of main pollutant emissions in the product life cycle after manure treatment was obtained as shown in Table S1 (Appendix).
2.2.3 Life cycle impact assessment
LCIA is a quantitative and qualitative characterization of the potential impact load on the environment based on pollutant emissions, resources and energy consumption obtained in the inventory analysis stage.
1) Classification
Classification is to classify the input and output data in the process of system life cycle into different environmental impact categories. Since CO2, CH4, NOX, N2O, NH3 and SO2 were the main gases often produced in the process of fecal composting, four closely related impact types are selected in this study: including global warming potential (GWP), acidification potential (AP), eutrophication potential (EP) and photochemical ozone synthesis potential (POSP).
2) Characterization
This study mainly considered four types of environmental impacts, including GWP, AP, EP and POSP. In this study, the equivalent factor method was used. The principle is that the contribution value of different pollutants (in the case of the same quality) to the same environmental impact type is different. Taking one of the pollutants as the benchmark, and its impact potential was regarded as 1, then the equivalent size of the reference material quality was obtained by comparing with the other pollutants. The calculation formula of product environmental impact potential was as follows:
$$\text{E}\text{P}\left(\text{j}\right)=\sum {EP\left(j\right)}_{i}=\sum [{Q\left(j\right)}_{i}\times {EF\left(j\right)}_{i}]$$
EP(j) —Impact potential for type j of environmental impact;
EP(j)i—Contribution of environmental impact factor i to environmental impact potential j;
Q(j)i —Emissions or consumption of environmental interference factor i;
EF(j)i —Equivalent factor of type i environmental impact factor to type j environmental impact.
3) Standardization
This paper used the world per capita environmental impact potential released by Stranddorf as the environmental impact benchmark (Lindley et al., 2019).
4) Weighted evaluation
The weight coefficients of global warming, environmental acidification, eutrophication, photochemical ozone synthesis and inhalable particles were 0.15, 0.32, 0.36, 0.32 and 0.11, respectively. Comprehensive environmental impact calculation formula was as follows:
$$WP\left(j\right)=\sum WF\left(j\right)·NP\left(j\right)$$
WP(j) —Integrated environmental impact potential.
WF(j) —Weight factor for type j environmental impacts.
NP(j)—Standardized impact potential.
2.3 Emergy analysis
The methodology of emergy analysis and its steps has been explained at (Odum, 1996; Odum, 2000). Emergy analysis consists of several successive steps:
1) drawing the process diagram and input and output flows;
2) using the system diagram to create an evaluation table for energy, materials, environmental services, money and labor flows. In this table, all input and output flows are estimated in their common units, and each item is multiplied by its solar conversion rate (the ratio of the total emergy used to the energy or mass of the product, in units sej/J or sej/g) in order to convert into emergy unit;
3)calculating a set of emergy indicators.
The energy system diagram was shown in Fig. 2 and the system boundaries were consistent with the LCA, both starting at fresh and ending at dairy manure production as a mattress. In the diagram, the energy input of the two fecal regeneration bedding systems was mainly divided into two categories: one was "free energy": sun, wind, rain and cow dung were the renewable environmental resource (R), which were used in the process; non-renewable environmental resource (N) included land use. Another one was “purchase energy”: flows of labor were Renewable industrial auxiliary energy (FR), meanwhile flows of repair and maintenance, asset depreciation and electricity were non-renewable industrial auxiliary energy (FN). Last but not least, the cow bedding and biogas slurry were the yield of process (Y). And the emergy conversion rates for the two systems which included all input and output flows under study were described in Table S2(Appendix A).
Moreover, the emergy indices were employed to analyze the operating efficiency, ecological characteristics and sustainability of different fecal regeneration bedding systems, namely emergy yield ratio (EYR), emergy investment ratio (EIR), emergy self-sufficiency ratio (ESR), renewable emergy ratio (RER), emergy sustainability index (ESI), environmental loading ratio (ELR) and emergy wastement ratio (EWR). The emergy indices were described in detail in Table S3(Appendix A).