Lowry Pits Chel 1

Gibbs House Compost Heat Recovery System
Funded by a Student Sustainability Grant
Fall 2014 Allocation

Final Project Report

Kelsey Pitschel and Elijah Lowry

Spring 2016

Special thanks to: Joshua Schultz, Derek Kanwischer, Dr. Harold Glasser, and the WMU Office for Sustainability, WMU
Landscape Services and WMU Facilities Management.
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I. Abstract
The project included the design and construction of a smallscale compost heat recovery system.The system functions as a
compostpowered water heater to provide hydronic heating to hoop house grow beds. The primary objective was to design
and test a system that could easily be constructed and utilized by farmers or rural landowners, with little prior experience in
hydronic systems or composting. The second objective was to identify a natural and widely available insulation material for
the radiant tubing system, to act as an alternative for polystyrene foam board. A third objective was to collect extensive data
on the performance of the system to provide insights on the potential for this type of system to be an economic and practical
solution for winter hoophouse heating. This study was made possible through grant funding provided by a student
sustainability grant, a student initiated and funded grant program that is facilitated by Western Michigan University. In the
Fall of 2014, $6,449 was awarded to purchase materials for the radiant tubing system, bulk compost materials, temperature
sensors and a Design plan from Gaelan Brown and Agrilab Technologies. The final system provided soil temperatures
between the ranges of 40F to 70F, which targeted the design soil temperature of 50F to 75F. Although the system was labor
intensive to construct, the system was able to function with little maintenance for over seven months.
Keywords: compost heat recovery, compost powered water heater, hoop house winter heating, closed loop system, winter

farming.
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II. Table of Contents
Item Page No.
I. Abstract 2
II. Table of Contents 3
III. Introduction 4
IV. Best Practice Review 5
V. Methodology 6
VI. Data and Results 16
VII. Conclusions 19
VIII. Limitations and Recommendations 20
IX. List of Resources and Contacts 21
X. References 22
XI. Appendices 23
A. Appendix A: System Floor Plans and Sections
B. Appendix B: Mound Sensor Locations
C. Appendix C: Agrilab Feasibility Study
D. Appendix D: Monthly Temperature Drop Plots
E. Appendix E: Monthly Mound Vertical Temperature Plots
F. Appendix F: Monthly Mound Horizontal Temperature Plots
G. Appendix G: Monthly Grow Bed Temperatures, Head
H. Appendix H: Monthly Grow Bed Temperatures, Foot
I. Appendix I: Manifold Shop Drawing
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III. Introduction
The Gibbs Farm is an active incubator for the advancement of sustainability at Western Michigan University. Recent onsite
agricultural developments include two constructed hoophouses with rows of seasonal vegetables and a cinder block
constructed worm bin. The Gibbs House property is located in Kalamazoo, Michigan (42.291707, 85.587229). The plant
hardiness zone is classified as 6A, with an average annual extreme minimum of 10F to 5F [13] . The regional abiotic
constraints of the michigan climate limits the growing season from April through October [2]. Hoop houses have gained
popularity in northern climates, due to potential increased profits from extended summer crop production periods.
Hoophouses also make it possible for growers in northern climates to produce cold season crops throughout the winter,
increasing potential for local sourcing of vegetables year round. Heating hoophouses in the colder months is not common
but can help maintain comfortable working conditions and optimal growing temperatures of 35F 85F [ 14] In order for
heating to be viable, the utility costs must remain minimal. This is typically done by using the conventional method of
heating a hoophouse or greenhouse with a propane heater [7]. This energyintensive solution is undesirable due to the
fossil fuel input and relatively high cost of operation. A low cost and low environmental impact heating system has the
potential to increase yields that would be attractive to Michigan farmers, as over half of Michigan farms recorded net losses
in 2007 [2]
.

In this study we explore the feasibility of heating grow beds of a Michigan hoophouse from October through April using
appropriate technology with a low environmental impact, low initial investment, low maintenance costs and simple
construction requirements. We chose to explore compost heat recovery technology known as the Jean Pain style compost
heater. The compost heat recovery system or compost powered water heater utilizes heat generated from the microbial
metabolization of organic material [4]. The bulk materials used in this type of system consist of wood chips, sawdust, and
manure, which are generally low cost and accessible in rural areas. The emitted heat is transferred via radiant tubing into
heat exchange zones underneath grow beds of a hoophouse. Despite dozens of examples of small scale Jean Pain
mounds, no businesses in the United States specialize in building the mounds, [5] and there is a significant lack of
comprehensive studies on their economic feasibility, design parameters, and system performance.

Our system design explores the feasibility of heating grow beds directly with a heat load device in the form of radiant tubing.
This differs from most designs that first transfer the heated water into a water storage tank that acts as a “heat bank” [5]. By
removing the bulk storage tank we hope to circumvent heat loss from the intermediate storage tank. Another unique
approach utilized in our system is the core design inside the pile. The proposed system contains one large central core
consisting of 900’ of poly tubing wrapped around a 5’ diameter by 5’ tall wire mesh cage. Similar systems organize the
tubing in a spiral layered vertically throughout the pile, or contain several smaller cores. The aforementioned designs adds
to the time needed for construction and tear down. If our system performs according to the projected design it would result
in a simpler construction that is easier to install and disassemble, thus reducing the cost of construction and materials.

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IV. Best Practice Review

The compost heater design is based on a method first developed by Jean Pain (19301981). Jean was the caretaker of a
large forest in southern France and found that he could reduce the risk of forest fires by removing brush from the forest.
Pain utilized the excess brush by shredding and composting the wood in large piles and harnessing the heat energy and
methane gas produced from the microbial breakdown. Pain found that composting the woody material produced more net
energy than combustion. The sustainability benefits of this method are first derived from the conversion of biomass to
usable energy in the form of heat and methane gas. The conversion of sustainably harvested biomass is considered to be a
viable approach to managing greenhouse gas emission for energy production [9]. The system requires very little energy
other than the small input required to circulate water and the initial construction of the pile. The second benefit is the end
product of humus that can be used in place of petroleumbased fertilizers. Compost is known to slowly release nutrients,
increase the water capture capabilities of soil as well as increase its cation exchange capacity [3].

The economic feasibility of this type of system is dependent on the availability of the bulk materials and the demand for
radiant heat over a set period of time [5]. It has been demonstrated that if the bulk material used in the pile are collected
properly form a nearby woodlot or forest the practice can improve the health of the forest while producing compost with a
greater value than the initial materials [1]. Jean Pain was able to yield the equivalent of 1 liter of high grade petrol in energy
capture and 8.5kg of humus for every 10 kg of chipped brush and even with the costs of operations labor and materials the
system would provide a profit after the first operation [6]. The Jean Pain’s system has recently gained interest in the
professional and academic field as an alternative energy source with the potential for profits. There are several examples of
successful large scale operations that are based on his method.

Diamond Hill Custom Heifers in Sheldon Vermont implemented a compost energy capture system in 2005, the system heats
the floors of a large barn and the water for calves’ milk. Their system captures hot water vapor from compost made mostly
of cow manure and bedding through aerobic composting. Aerobic composting is favored in their case because it utilizes the
waste product more efficiently than anaerobic digestion [10]. Diamond Hills is able to capture energy from their animal
waste products and convert it into a stable fertilizer. By composting the animal waste the farm is better able to comply with
Medium Farm Operations standards for dealing with animal waste in Vermont. The system also reduces the potential for
waste runoff into the Missisquoi River watershed [11]. The downfall of this type of system is that it requires a large initial
investment in infrastructure and a continued investment in maintenance. The goal of this project was to test the feasibility of
a small scale system that could be constructed with minimal initial investment and expertise.

Much of the initial design plans and goals for the small scale system were based on a University of Massachusetts Amherst
graduate thesis project. Graduate students Gath Schwellenbach and Katrina Spade were awarded grant funding to
construct a modified Jean Pain style compost heating system. Their feedstock material consisted of 10 Y 3 of brushwood
and 10 Y 3 of sawdust. Once constructed, the pile was insulated with straw bales. The hydronic system inside the pile
included 900 feet of pex tubing distributed into 6 layers throughout the pile. Their plan was to install radiant flooring into their
greenhouse to heat grow beds through winter [1]. Unfortunately, their greenhouse was not constructed in time to install the
heating zones and their system failed due to lack of moisture in the pile.

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V. Methodology

The following section demonstrates the methods used to design and construct all components of the compost heat recovery
system.

A. System Design
The design of the compost mound took place during the Fall of 2014 and the Spring of 2015. WMU Student Sustainability

Grant funding was allocated in the beginning of the Fall 2014 term. Preliminary design indicators were developed through
analyzing the UMass Compost Heater Project, and exploring the “CompostPowered Water Heater” book and manual
provided by AgriLab and Gaelan Brown [1].

Design criteria was determined by analyzing the existing conditions of the hoophouse. Surface area able to be utilized for
grow beds was calculated for 480 SF. The desired temperature range of 50F to 75F for the grow bed soil and expected
internal compost mound temperature range of 110F to 150F were used to calculate discrete heat transfer events via
conduction through red pex tubing. Refer to Equation 1 for the conduction equation. Assumptions include steady state flow
through radiant tubing, all heat transferred from water in tubing to soil, control volume, and no water in superheated state.
Table 1 shows relevant values used in the calculation.

q = − kA dT
dx Eqn. 1

Table 1: General System Parameters
Design Parameters
Total hoophouse floor area 1440 SF
Hoophouse surface area available for grow beds 480 SF total
160 SF each bed
Desired grow bed soil temperature range 50F to 75F
Expected compost mound temperature range 110F to 150F
Expected energy output of system due to hand analysis 10,000 Btuh/year

A general energy balance equation (Eqn. 3) was utilized to calculate the expected water temperatures in and out of the
mound. Based on the previously stated assumptions, Equation 3 demonstrates the simplified equation used to compute the
temperature in State 2 (water returning to mound), as shown in Figure 1.

q − w = Δe Eqn. 2
Qin − Qout + W in − W out = Σmθ Eqn. 3
Qout = W in − m(h1 − h2) Eqn. 4

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Where
Q = Thermal energy rate = m C
dT (kJ/s)
p
W = Work done by motor = C
p dT (Btu/hr)

3
m = Mass flow rate (m /s)
ᵯ = System energy per mass = h + pe + ke (Btu/lbm)
h = Enthalpy (Btu/lbm)

Fig. 1: Energy flow diagram for water tubing

Table 2: Energy Balance Values
Energy Balance Values, Given Energy Balance Values, Calculated
W, work done by motor 318 Btu/hr State 2
Q, thermal energy rate, expected 10,000 Btu/hr Enthalpy 58.74 Btu/lbm
m, mass flow rate 0.06852 lbm/s Temperature 90F, avg

3
V, Volumetric flow rate 0.0011 ft/s Pressure 2.226 psia
Enthalpy, state 1 97.99 Btu/lbm
Temperature, state 1 130F ,avg

After determining system values and parameters, a detailed Revit model was developed for the construction of the entire
system. Refer to Appendix A for Revit plans and sections.

The change in temperature across the entire system is demonstrated by the following relationship:

Btu/hr
ΔT = 500*GPM = 38.728 degF Eqn. 5

Where
Flow rate = 0.5 gpm
System energy = 9,682 Btu/hr

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B. System Construction
Construction of the system took place in several phases: grow bed construction, radiant tubing installation, manifold
construction, trench construction, core building, and mound construction. The building of the compost mound concluded the
final construction phase in October 2015. Various data loggers were installed throughout the grow beds and the compost
mound to record temperature and relative humidity at 30 minute intervals. Construction was primarily completed by
members of the permaculture team: Elijah Lowry, Josh Shultz, and Kelsey Pitschel. A daylong mound building workshop
with community volunteers took place in October 2015 to complete the building of the mound pile.
Phase 1: Grow Bed Construction
Three test grow beds were excavated in the 48’ by 30’ hoophouse in early June of 2015. The beds measure approximately
40’ long and 4’ wide, spaced 1’ apart. The excavation was performed with the assistance of a tractor and finished by hand
to reach a depth of approximately 16” to 18” . Each bed features a separate heating zone insulated with a unique material.
The design uses the insulation materials to compare alternatives to conventional polystyrene foam: cob/wine bottles, plastic
wrapped straw bales. Bed 1 is insulated with conventional 1’ polystyrene foam. Bed 2 (Fig. 2) is insulated with 10 straw
bales placed in sheets approximately 6”’ thick and encased in plastic film. The final bed was excavated to a depth of 18”
(Fig. 3) and insulated halfway with empty wine bottles placed horizontally in an interlocking order, 20’ long and 4’ wide.
The wine bottles were sealed together with 1’ of the earthen insulative material known as cob. the remaining 20’ of the third
grow bed was left without an insulation as a control.

Fig. 2: Zone 2 Straw Bale Insulation Fig. 3: Zone 3 Cob / Wine Bottle Insulation
Phase 2: Radiant Tubing Construction
As explained in the “grow bed construction” section each grow bed includes its own radiant heating zone. The radiant zones
were constructed using conventional ½” red pex tubing that was affixed using zipties to 1”x 2” spaced wire remesh, 4’ in
width and cut to the length of the grow beds (Fig. 4). Conventional ½” red pex tubing was chosen because it is more
maneuverable than conventional water tubing and rated to handle liquids up to 180F at 100 psi. The disadvantage of this
type of tubing is the thicker walls and small diameter makes it a less effective vehicle for heat exchange. The design allowed
for approximately 4’ of tubing to be connected to the hot supply portion of the manifold. The tubing was organized in 3’
diameter spirals with 1.5’ overlap that spanned from end to end of the wire remesh, the cold return line was run straight
back toward the manifold. Implications of this design decision are explained later in the Recommendations Section. The
total length of tubing for each bed was 350 linear feet. The tubing systems were placed directly on top of the insulation
material (Fig. 4) and covered with 8” of topsoil. A trench was dug from each bed to the manifold at 1’ below grade. The
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tubing that spanned the trench was wrapped in ½” foam insulation tubing, and sealed in aluminum foil tape. Once properly

insulated, the hot supply and cold return line were joined to the manifold.

Fig. 4: Radiant tubing affixed to wire mesh

Phase 3: Manifold Construction
The manifold was utilized to modulate the water flow between the zones and mound to each of the zones. The entire
manifold system included the components shown in Table 3. The shop drawing for the manifold is shown in Appendix I . The
manifold utilized a timer to control the system. The timer was set for 12 hour intervals for 4PM to 4AM during the coldest
part of the day, typically. The pump was not desired to run nonstop due to a reduced heat output from the mound. Images
of the completed manifold are shown in Figures 5 and 6.

Table 3: Manifold Components
Component Size
Hot / Cold Radiant Manifold 4 zone, T/P gauges
Expansion Tank Hydronic, 4 gal
Taco Pump ⅛ hp, 1” connectors
Air separator 1” line connectors
Pressure Gauge Direct line tiein
Pressure Relief Valve 1” thread
Electrical Timer Hourly settings, tied to pump
Copper piping and connectors 1”, sweat, threaded, and direct connect

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Fig. 5: Manifold with component labels Fig. 6: Completed manifold with timer

Phase 4: Trench Construction
The trench that spans the length between the center of the pile and the manifold inside the hoophouse measures
approximately 14 feet. The supply and return lines were cut to size with an extra 10 feet at the end to ensure they would be
able to connect with the tubing at the top of the core. The joint was made at the top of the core because it is the highest
point of the tubing system and allows for easy installation of water and propylene glycol into the hydronic system. The line
was buried to prevent it from impeding movement between the pile and the hoophouse and to protect the line from the
elements. The trench depth is not below the frost line, however the tubing is wellinsulated. The buried tubing was wrapped
in 1inch insulation and secured with aluminum foil tape. The tubing was then encased inside 4inch corrugated tubing for
protection and aeration (Fig. 7).

Fig. 7 : Trench between mound and hoophouse
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Phase 5: Core Construction
The core is the primary heat capture device of the system and was placed in the center of the compost pile. The core was
constructed using 1” poly tubing and 6” x 6” wire remesh. The wire remesh was used to construct a 5’ diameter and 5’ tall
cylindrical frame. The cylinder was constructed by coiling the wire mesh with a 1’ overlap, the free ends of wire remaining
where the cuts were made were bent back to lock the cylinder into form. The sharp edges were wrapped in 2 layers of
gorilla tape to reduce puncture hazards. 800’ of poly tubing was wrapped around the frame to match the design
specifications provided by Galen Brown. The poly tubing was affixed to the frame beginning with the hot supply end,
extending 3’ past the frame to later be attached to the underground lines. The tubing was run straight down the inside of the
cylinder and coiled back around the outside of the frame towards the top. The tubing was coiled around the frame starting
from the bottom with a 1.26’ gap left in between each revolution upwards (Fig. 8). Once the coils reached the top, the line
was run down the inside of the frame once again. The tubing was then coiled again around the outside of the pile filling in
the gaps left from the fist revolutions. once the second coils reached the top of the frame the line was cut leaving an
additional 3’ to connect to the underground line as the return line (Fig. 9). Both the supply and return lines were aligned
vertically and zip tied together. The coils around the frame were fastened to the frame every three feet using zip ties. The
coiled tubing is not a single continuous piece of tubing, instead several sections were jointed together to make handling
easier. For each joint made, two hose clamps were attached to each end of the joint, 4 total for each joint. The clamps were
arranged on each end to have the tightening bolt facing opposite sides of the tube and away from the tubing above and
below the joint. It was crucial to ensure that each joint was tightly clamped to prevent any leaks. The underground lines are
over flowing outside the core in Figure 9 and the extra tubing left to connect to the lines is shown at the top of the core. The
joint was made at the top of the pile because it would be the point at which the liquid was pumped into the system.

Fig. 8: First pass of tubing around core Fig. 9: Core in place, surrounded by corn crib

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Phase 6: Mound Construction
Materials
The bulk material quantities and ratios were based of the compost powered water heater specifications for a small scale
system [A]. The total volume of the bulk materials was 40 Y 3 with 24 Y 3 hardwood mulch provided by WMU’s landscape
services. The mulch was produced from the excess woody material left from general maintenance of the campus grounds.
The remaining materials were 12 Y 3 of sawdust donated from a local sawmill and 4 Y 3 horse manure donated from
Woodham Farms located 10 miles away in Kalamazoo, MI. The material had to be well mixed to increase the uniformity of
microbial colonization and breakdown. The material was premixed using the bucket of a tractor. To keep the ratio of material
consistent 6 buckets of mulch were loaded for every 3 buckets of sawdust and 1 bucket of manure. The mixing took
approximately 10 hours of tractor operation.

Process
The total diameter of the compost pile measured 17’ in diameter including the straw bales placed around the pile for
insulation. To prepare for the pile, the staging site was excavated three inches below grade to retain moisture from the pile.
The area was also graded so that the pile would lay flat. 4” of wood chips were placed at the base and 100’ of 4” corrugated
perforated tubing was coiled around the base of the pile to allow for aeration of the pile. The tubing was buried in an
additional 4” of woodchip material and the core was placed on top of the tubing. With the tubing and core in place and
installed into the underground lines connecting the core to the manifold a corn crib 13’ in diameter was placed around the
perimeter of the pile to allow structural support for the bulk material of the pile. The corn crib was donated by landscape
services and was very useful in maintaining the structure of the pile during construction. During construction of the pile 3 of
the panels were installed in place and the fourth panel was left unattached to allow access into the area for material
transport. Straw Bales were stacked behind the panels and fastened to the corn crib panels using bailing twine to prevent
bulk material from spilling over from the pile area (Figure 10).

Fig. 10: Volunteers add wood chips, manure, and sawdust to mound

Once the material was premixed and ready to be installed the Office for Sustainability hosted a work day at the Gibbs Farm
in October of 2015 to help build the pile and learn about the project. The majority of the bulk material was installed with the
help of 12 volunteers using wheel barrows (Fig. 11) During the infilling process all the material was heavily saturated with a
high flow garden hose, to ensure that the material had at least a 70% moisture content. This was critical to the success of
the pile as past projects have failed due to the material being too dry. Once the pile reached a height that wheel barrow
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installation was no longer viable, the front panel was installed and the rest of the material was loaded in using a tractor.
Eighty straw bales were stacked around the pile in a staggered pattern and fastened using baling twine (Fig. 12). Once the
pile was finished, the water and glycol were pumped into the system and the top strawbale layers were added to the pile
(Fig. 12). The total construction of the pile required 12 volunteers, a front loading tractor, and a full 8 hour work day. The
finished pile is shown in Figure 13.

Fig. 11: Volunteer workday, midprogress Fig. 12: Completed inner mound

Fig. 13: Fully constructed compost mound with insulation

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C. Data Collection Methods

Temperature and moisture data was collected throughout the system using (Onset Hobo Ⓡ Data Logger) data sensors and
software. Temperature data is recorded every 30 minutes and stored within the sensor. Sensors are extracted every 30
days in order to analyze continual system performance.

Compost Mound Data
Temperature data is collected using six discrete UA00263 HOBO pendants distributed throughout the pile to collect
temperature data. Refer to Appendix B for a section view of sensor locations within the pile. The TL1 data logger is
enclosed in a 6” PVC pipe and affixed directly on the core, approximately 2.5’ in from the top of the pile. The M1, M2 and
M3 data loggers are all contained inside a 7’ PVC vertical pipe that was modified to have a pointed end allowing it to
penetrate to the bottom of the compost pile. The M1 data is located 2.5’ deep inside the pile to align with the TL1 sensor on
the vertical plane. The M2 sensor is located 2’ below the M1 sensor and the M3 sensor is located 2’ below the M2 sensor.
The vertical arrangement of the sensors provides information on what kind of heat output is produced throughout the pile to
reveal a potential temperature gradient. The M4 sensor is enclosed in a PVC pipe similar to the others located at a depth of
2.5”: in between the core of the pile and the surrounding corn crib. The actual location of the sensor is approximately 24” in
from the outside edge of the pile. At the same depth of 2.5”, the M5 sensor is placed directly outside the pile inside a open
ended PVC pipe, against the corn crib in between the straw bales. The combination of the sensors from Tl1, M1, M4, and
M5 provide information on the heat loss from the core of the pile to the external regions of the pile that are more exposed to
the elements. This reveals information regarding the insulation performance of the straw bales.

Grow beds
Temperature data was collected from each of the grow beds using seven discrete 6 UA00263 HOBO pendants. Refer to
Appendix A for location of each sensor. The data loggers were placed PVC pipes approximately 18’ in length with open
ends at the bottom. The pendants were hung from inside the PVC so that the sensors were flush with the end of the pipe.
Holes were dug to 1” above the radiant tubing inside the grow beds, the pipes were placed in the holes so that each
temperature sensor was 1” away from the radiant tubing. The design of the sensor casing is shown in Figures 14 and 15. In
Zone 1, a data logger was placed at the head and foot of the bed the same was done for Zone 2. Zone 3 contains 3 sensors
one at the head of the cob insulation and one at the end of the cob insulation and a final sensor at the end of the control
section of the bed with no insulation. The sensors were placed at the opposite ends of the beds to allow for the heat loss
throughout the beds allowing us to calculate the R value and effectiveness for each insulation material.

Fig. 14: HOBO sensor and PVC casing Fig. 15: Sensor in growbed

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Ambient Temperature and Relative Humidity
To account for external temperature both inside the hoophouse and outside two UX100003 HOBO Temperature and
Relative humidity dataloggers were installed. One data logger was placed inside the hoophouse near the manifold, away
from the entrance to mitigate influence from the outside draft. The remaining sensor was placed outside the hoop house
inside a half enclosed PVC pipe to protect it from moisture. Relative humidity and temperature data was also recorded every
30 minutes and collected every 30 days with the rest of the sensors.

D. Cost Summary
The cost summary featured in this section is based on the parameters for this particular design. This cost estimate does not
account for the cost of labor. For this system a plumber was hired to construct the manifold and charge the system with a
propylene glycol mix. We would like to note that all of the bulk materials were donated which reduced the final cost of the
system by an estimated $ 1,360. Included in the summary is the value added byproduct of compost which is left over after
the system completes its lifecycle. With an estimated 10% reduction of the bulk material during the breakdown process the
system would provide 36 Y 3 of finished compost,with an estimated value of $720 at bulk retail price. If the cost of the
materials are factored out and the value of the compost is included, the system material costs could be reduced to $1263.

Table 4: Compost Mound and Manifold Components Cost Estimate
Estimated Cost of 40 Y 3 Compost Pile, 480 ft2 Heated Grow Beds
Unit Price Quantity Cost
Compost Powered Water heater
Shredded hardwood mulch (per Y 3 ) 26 40 1040
3
Sawdust (per Y ) 6 20 120
3
Manure (per Y ) 40 5 200
Straw bales 3 80 240
Aerated Tubing 50 1 50
Sub total $1650
Hydronic System
Circulator Pump 188 1 188
Pex Tubing (300’) 83 4 332
Poly tubing (300’) 150 3 450
Hardware N/A N/A 70
Steel Wire Remesh 98 2 196
Insulation 17 15 255
Manifold 142 1 142
Misc Manifold N/A N/A 350
Sub total $1983
Total $3633
Donated Materials
Compost byproduct (per Y 3 ) 20 36 +$720
Free bulk materials +1650
Total After Savings $1263
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VI. Data and Results
Average Temperature Drop
This section will demonstrate temperature trends for the lifetime of the mound thus far. Refer to Appendices D, E, F, G and
H for monthly plots. Figure 16 shows the average temperature drop across the zone bed lengths since accurate data
collection began in December. Zone 3 for cob and control zones began in January 2016 when reliable data became active.
As expected, the temperature drop reaches generally higher values later in the life of the mound. However, there is a
cyclical downward trend after reaching a peak in temperature drop. This can be associated with weather fluctuations and
other factors. The foam board is noted to have a higher temperature drop over most time, but it shall be noted that it is
located at the outermost boundary of the hoophouse and may incur more heat loss than the inner zones. The straw bales
maintain a fairly neutral temperature loss, suggesting its competitive insulation value compared to the foam board and cob.
Cob is among the lowest temperature drop, suggesting a surprisingly high insulation value. However, the cob zone is only
half the length of the foam and straw zones. In February, it appears that no insulation behaves similarly to the cob.

Fig. 16: Average Temperature Drop Across Zone Lengths for Life of Mound

Mound Temperatures
Figure 17 demonstrates the temperature gradient vertically within the compost mound. The internal temperatures are plotted
with ambient outdoor air temperature for context. As shown, overall mound temperature increases dramatically around
January 22 without a noticeable increase in ambient air temperature. This anomaly can be attributed to cyclical heat
patterns of the mound material.

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Fig. 17: Mound Vertical Temperature Gradients for Life of Mound

Figure 18 demonstrates the temperature gradient horizontally within the compost mound. This relationship suggest the
performance of the external straw bale insulation for the mound. The internal temperatures are plotted with ambient outdoor
temperature for context. As shown, the inner side mound temperature is much greater than the temperature at the corn crib
outer shell. This shows that the straw bales provide a certain level of appropriate insulation for the mound.

Fig. 18: Mound Horizontal Temperature Gradients for Life of Mound

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Soil Bed Temperatures
Figure 19 shows the actual temperatures within the grow bed soil across the lifetime of the mound thus far. Accurate
ambient air temperature within the hoophouse began in January 2016, as shown by the orange line below. The head
temperature of Zone 3 fluctuated more than the other zones prior to the beginning of January. However, after this point, all
of the grow beds had similar head temperatures. This trend assures that the manifold appropriately distributed the hot
supply water to each bed from the mound.

Fig. 19: Average Temperature at Head of Grow Beds for Life of Mound

The average temperatures at the foot of the grow beds is shown in Figure 20. The trend is similar to the head temperatures
which ensures limited anomalies when it comes to bed temperature overall behavior.

Fig. 20: Average Temperature at Foot of Grow Beds for Life of Mound
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VII. Conclusions

The compost heat recovery system is a viable alternative to heating hoop house grow beds during the winter. The system
has many limitations, as discussed below, including labor time, materials cost, and seasonal fluctuations in temperature.
The system provided desirable output temperatures within the range of 40F to 70F. The system is able to be replicated for
$3,633 for cost of materials and equipment for one life cycle. Local farmers and community members donated manure and
other bulk materials to reduce the construction cost for this system to $1,263. In order to reduce labor costs and
construction time of the mound, a public volunteer day with the use of a front load tractor is suggested. The system provides
an opportunity to discuss appropriate technology for smallscale rapidly renewable energy solutions.

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VIII. Limitations and Recommendations
Radiant Tubing Pattern
The grow bed radiant tubing zones would benefit from a redesign. The current concentric circles design creates overlap in
the tubing, which can create hot and cold spots throughout the system. The recommended spacing for ½” red pex is 8” to
12” on center to provide even heating within the limits of the fluid temperatures [11]. The concentric circle design also fails to
evenly distribute heat throughout the regions of the beds with the greatest heat demands. The edges of the beds are the
most exposed and demand the greatest amounts of heat. Conventional radiant tubing designs send the hot supply around
the edges of the concrete slabs in a counter flow pattern where heat demand is greatest at 6” spacing on center and
arrange the return line towards the middle of the slab where heat demand is the lowest with spacing at 12” on center [12].
The change in the layout pattern would also be beneficial by reducing the length of each circuit. The current circuit length for
each bed exceeds the recommended length for the tubing which is 300’ [8]. The current system has a total circuit length of
350 feet. This allows for the liquid to lose too much heat before returning to the compost pile which can exceed the
recommended change in temperature of 1015 degrees Fahrenheit.

Design of Core Configuration
The current design of core essentially creates two separate piles: within coil tower and outside of the coil tower. Since the
coil tower creates two different regions of mound material, the mound does not reach expected temperatures to heat the
water. It is suggested for future applications to lay in water tubing either much more spaced out on the coil tower or to
eliminate the tower design completely. Best practice designs often loosely coiled the water tubing throughout the pile
without a firm structure. This design was not pursued due to its longer tear down and time and potential for tubing
punctures.

Additional Recommendations
The study could have gained much more insight with collaborations among Biology professors at WMU to better understand
the breakdown of material in the mound and the associated heat cycles. Although the straw bales provided a fairly good
insulation around the outside of the mound, additional plastic insulation may be beneficial.
20

IX. List of Contacts
Refer to Table 4 for a list of contacts and resources utilized throughout the project.

Table 4: Listing of Contacts and Information
Contacts and Resources
Contact / Resource Resource Information
Gaelan Brown gaelan@agrilabtech.com
http://agrilabtech.com/
Woodham Farms Manure 35480 675th Ave, Portage, MI
Aaron Dykstra Wood chips and sawdust WMU Landscape Services
Andy Gene Sawdust P. (269) 3735455
Josh Shultz System design consulting joshkhan2001@gmail.com

21

X. References

[1] Brown, Gaelan. “The CompostPowered Water Heater.” The Countryman Press . Woodstock, Vermont. 2014.

[2] Conner, David S., et al. "Hoophouse contributions to economic viability: Nine Michigan case studies." HortTechnology
2010

[3] Cooperband, Leslie. "The art and science of composting." Center for Integrated agricultural systems 2002.

[4] de Bertoldi, M. de, G. et Vallini, and A. Pera. "The biology of composting: a review." Waste Management & Research 1.1
(1983): 157176.

[5] Gorton, Sam. "Cornell Small Farms Program." Cornell Small Farms Program Compost Power Comments . N.p., 2012.
Web. 2016.

[6] Pain, I. "The methods of Jean Pain: Another kind of garden."
Commite International Jean Pain, Hof ter Winkelen,
Londerzeel, Belgium 1972.

[7] Rader, J., Handeen, D., & Singh, V. “CoolClimate Greenhouse Resource.” University of Minnesota Extension 2013.
Web. 2016.

[8] Radiantec. "Radiantec Installation Manuals." Radiant Heating Installation Manualseasy to Understand, Pictures and
Diagrams. Radiantec Company, Inc 2014. Web. 2016.

[9] Ragauskas, Arthur J., et al. "The path forward for biofuels and biomaterials." science 311.5760 (2006): 484489.

[10] Smith, Matt, and John Aber. “Heat Recovery from Compost: A Guide to Building an Aerated Static Pile Heat Recovery
Composting Facility.” UNH Cooperative Extension 2014. Web. 2016.

[11] Tucker, Molly Farrell. BioCycle 2006. Web. 2016.

[12] Uponor. “Wirsbo Installation Handbook.” Wirsbo, Section 7. 6th ed. Apple Valley: (1999): 4243.

[13] USDA. “Plant Hardiness Zone Map.” PRISM climate Group, Oregon State University 2012. Web. 2016

[14] Whiting, D., O'Meara, C., & Wilson, C. “Vegetable Planting Guide.”
Colorado State University Extension 2014. Web.
2016.

22

XI. Appendices
The following appendices are attached following this page.

C. Appendix C: AgriLab Feasibility Study

23

PLUMBING SPECIFICATIONS
1 ALL CONSTRUCTION SHALL BE IN ACCORDANCE WITH

SYMBOLS & ABBREVIATIONS WMU SAFETY STANDARDS.
2 TOTAL COMBINED SURFACE AREA FOR RADIANT HEATING
DESIGN IS 549.5 SF. TOTAL HEATING SURFACE AREA
KEYED NOTE ALLOWABLE BY COMPOST MOUND IS 600 SF.
3 RADIANT ZONES 1 - 3 SERVE GROW BEDS 42 FT LONG BY 4
T TEMPERATURE SENSOR - HOBO FT WIDE. TUBING INSTALLED 1 FT BELOW GRADE.
4 RADIANT ZONE 4 SERVES VERMICOMPOST BIN APPROX. 10
FT LONG BY 5 FT WIDE. TUBING INSTALLED 1 FT BELOW wmich.edu/sustainability
TA TEMPERATURE SENSOR - ARDUINO
GRADE. SHEET METAL FIT TO SIZE BETWEEN TUBING AND
WORMS.
P CIRCULATION PUMP - WATER TYP
5 TOTAL HEAT CAPACITY TO BE DISTRIBUTED TO ZONES
LESS THAN OR EQUAL TO 10,000 BTU/HR DELIVERED BY GIBBS HOUSE
MANIFOLD COMPOST MOUND.
COMPOST HEAT
6 MAXIMUM WATER TEMPERATURE WITHIN TUBING NOT TO RECOVERY SYSTEM
F FLOW METER EXCEED 150F.
Project Name
7 TYPICAL WATER VOLUMETRIC FLOW RATE NOT TO DROP
J JUNCTION BOX BELOW 0.5 GPM.
8 PUMP SHALL BE BASED ON 1/8-HP TACO 009-F5 OFFICE FOR

CIRCULATION PUMP. 115 V REQUIRED, 60 HZ, 1.4 AMPS. SUSTAINABILITY
9' - 11"
9 COLD RETURN TO ENTER BOTTOM OF TOWER. HOT
3 SUPPLY TO LEAVE AT TOP OF TOWER.
WESTERN MICHIGAN
LEACHATE ZONE 4 - VERMICOMPOST
PROTAPOD PROTAPOD PROTAPOD
4' - 7"
BIN UNIVERSITY
3 2 1
T
KEYED NOTES Client Name
BLACK SOLIDER FLY LARVAE 1 MANIFOLD TO BE MOUNTED INSIDE HOOP HOUSE FRAME.
VERIFY FACTORY FLOW METERS IN FIELD.
2 RIGID POLYMER FOAM BOARD TO SERVE AS INSULATION

7
FOR ZONE 1. PACKED STRAW TO SERVE AS INSULATION
FOR ZONE 2. COB WINE BOTTLES TO SERVE AS
TA
1/2" RED PEX FOR ALL
J
INSULATION FOR EAST HALF OF ZONE 3.
RADIANT FLOORING, ZONE 3 - GROW BED 3
BEGIN AFTER MANIFOLD
T
TA
T TA
3 RADIANT LINES TO AND FROM VERMICOMPOST BIN TO BE
DUG 1 FT BELOW GRADE AND INSULATED USING POLYMER
1 FOAM CONDUIT.
T
J
TA
6
ZONE 2 - GROW BED 2
T x4
T
TA
4 SUPPLY AND RETURN LINES TO ENTER AND EXIT COIL TOWER
4-WAY MANIFOLD Fx2
REFER TO P502 AT TOP. COIL DOWN WITH 1" SPACING, THEN ROUTE COILING
UP BETWEEN SPACES. INSTALL WITH HANDLE FOR EASY
24
T
TA
TEAR DOWN.
ZONE 1 - GROW BED 1
Fx2
4' - 0"
T
TA
1 GAL
5 CONDUIT 1 FT BELOW GRADE BETWEEN HOOP HOUSE AND
P TANK MOUND.
2
COMPOST HEATER w/
P J 42' - 0"
5 6 TEMPERATURE SENSOR TO BE PLACED IN ORGANIC RADIANT FLOORING
MATERIAL. ADD TAG TO AVOID DAMAGE DURING TURNING.
1" BLACK
SCHEMATIC
4 POLY Sheet Name
7 COB INSULATION TO END HALFWAY AT 20 FT FROM HOT
MOUND SUPPLY INTAKE OF ZONE 3.
HEIGHT:
7.5 FT
COIL TOWER
8 ARDUINO CIRCUIT AND JUNCTION BOXES TO BE INSTALLED
9 SEE KEYED ONTO 2X4" BOARDS SECURED VERTICALLY INTO GROUND.
NOTE 9 FOR
MOUND INFILL
JUNCTION BOX TO TIE DIRECTLY TO NEAREST ELECTRICAL
PANEL.
2
P502
9 COMPOST MOUND MATERIALS:
40 CU.YD. SHREDDED HARDWOOD MULCH
20 CU.YD. SAWDUST
5 CU.YD. MANURE
HOOP HOUSE FLOOR PLAN
80 BALES OF STRAW FOR OUTER LINING
1
1/4" = 1'-0"
Office for Sustainability

Western Michigan University
1903 W Michigan Ave
Kalamazoo, MI 49008
Kelsey Pitschel
(810) 599-2396
Project Number 15-0720.00
Date 7/20/2015
Drawn By KP
Checked By DK
Scale
P501
1/4" = 1'-0"
SENSORS LISTING PLUMBING SPECIFICATIONS
HOBO SYSTEM:
1 ALL CONSTRUCTION SHALL BE IN ACCORDANCE WITH
1 (1) WATER TEMPERATURE - MANIFOLD HOT WATER WMU SAFETY STANDARDS.
OUTPUT. ADHERE TO OUTSIDE OF TUBING.
2 TOTAL COMBINED SURFACE AREA FOR RADIANT HEATING
DESIGN IS 549.5 SF. TOTAL HEATING SURFACE AREA
2 (3) WATER TEMPERATURE - MANIFOLD COLD WATER ALLOWABLE BY COMPOST MOUND IS 600 SF.
RETURN LINES. ADHERE TO OUTSIDE OF TUBING.
3 RADIANT ZONES 1 - 3 SERVE GROW BEDS 42 FT LONG BY 4
FT WIDE. TUBING INSTALLED 1 FT BELOW GRADE.
3 (2) SOIL TEMPERATURE - ZONE 1 - GROW BED 1. PLACE IN
WIND COILINGS AROUND SOIL. 4 RADIANT ZONE 4 SERVES VERMICOMPOST BIN APPROX. 10
FT LONG BY 5 FT WIDE. TUBING INSTALLED 1 FT BELOW wmich.edu/sustainability
TOWER. SECURE USING ZIP-
TIES. SUPPLY AND RETURN GRADE. SHEET METAL FIT TO SIZE BETWEEN TUBING AND
4 (2) SOIL TEMPERATURE - ZONE 2 - GROW BED 2. PLACE IN WORMS.
ENTER/EXIT AT TOP. SOIL.
5 TOTAL HEAT CAPACITY TO BE DISTRIBUTED TO ZONES
LESS THAN OR EQUAL TO 10,000 BTU/HR DELIVERED BY GIBBS HOUSE
SEE KEYED NOTE 5 (3) SOIL TEMPERATURE - ZONE 3 - GROW BED 3. PLACE IN
9 COMPOST MOUND.
9 FOR MOUND SOIL. PLACE THRID SENSOR BETWEEN INSULATION COMPOST HEAT
INFILL ZONES. 6 MAXIMUM MOUND TEMPERATURE NOT TO EXCEED 150F. RECOVERY SYSTEM
MAXIMUM WATER TEMPERATURE NOT TO EXCEED 100F.
Project Name
6 SENSORS DO NOT REQUIRE ELECTRICAL HOOK UP.
7 TYPICAL WATER VOLUMETRIC FLOW RATE NOT TO DROP
REMOVE FROM LOCATIONS DURING DECONSTRUCTION.
BELOW 0.5 GPM AND NOT TO EXCEED 1.5 GPM.
REFER TO SD CARD FOR DATA.
7' - 6"
3" CORRUGATED POLY COIL
CONDUIT FOR TRANSMISSION TOWER
AT GRADE 8 PUMP SHALL BE BASED ON 1/8-HP TACO 009-F5 CIRCULATION OFFICE FOR
LINES. RUN IN LOOSE COILS 1' ARDUINO SYSTEM: PUMP. 115 V REQUIRED, 60 HZ, 1.4 AMPS. TIE ELECTRICAL SUSTAINABILITY
BELOW GRADE INTO EXISTING PANEL.
1 (3) WATER FLOW METER - MANIFOLD HOT WATER 9 COLD RETURN TO ENTER BOTTOM OF TOWER. HOT
OUTPUT FOR ZONES 1, 2, AND 3. INSTALL IN LINE SUPPLY TO LEAVE AT TOP OF TOWER. WESTERN MICHIGAN
13' - 6" COLD RETURN
FOLLOWING MANIFOLD.
UNIVERSITY
HOT SUPPLY 2 (2) SOIL MOISTURE - HEAD ZONE 3 AND VERMICOMPOST Client Name
BIN. INSTALL DIRECTLY IN SOIL. KEYED NOTES
3 (7) SOIL TEMPERATURE - LOCATIONS AS SHOWN. INSTALL

DIRECTLY IN SOIL. 1 MANIFOLD TO BE MOUNTED INSIDE HOOP HOUSE FRAME.
MOUND SECTION VIEW VERIFY FACTORY FLOW METERS IN FIELD. AIR PRESSURE
2
3/8" = 1'-0" TEST PRIOR TO FINAL TIE IN.
4 SENSORS REQUIRE CONTINUOUS POWER SUPPLY VIA
JUNCTION BOXES. REMOVE SENSORS DURING 2 RIGID POLYMER FOAM BOARD TO SERVE AS INSULATION
DECONSTRUCTION. REFER TO SD CARD FOR DATA. FOR ZONE 1. PACKED STRAW TO SERVE AS INSULATION
FOR ZONE 2. COB WINE BOTTLES TO SERVE AS
INSULATION FOR EAST HALF OF ZONE 3.
PUMP SIZING CALCULATIONS 3 RADIANT LINES TO AND FROM VERMICOMPOST BIN TO BE

DUG 1 FT BELOW GRADE AND INSULATED USING POLYMER
FOAM CONDUIT.
SIZING CALCULATIONS BASED ON:
F = Q / (500*dT) 4 TOWER TO HOLD COILINGS WITHIN COMPOST MOUND.
CONSTRUCTED WITH 5' CATTLE PANELS AND TIED
25
RATE OF HEAT TRANSFER, Q 10,000 BTU/H TOGETHER VIA METAL ZIP TIES.
P RELIEF VALVE
ATTACH ALL PIPING AND AIR SEPARATOR TEMP DROP ACROSS LOOP 20 F
SWEAT CONN.
EQUIP WITH 1" SPLIT BOTH SIDES SWEAT CONN. BOTH SIDES TARGET FLOW RATE 1 GPM 5 CONDUIT 1 FT BELOW GRADE BETWEEN HOOP HOUSE AND
RING HANGERS MOUND. PLUMBING DETAIL
1" PEX
Sheet Name
6 TEMPERATURE SENSOR TO BE PLACED IN ORGANIC
1" CU HW FROM MOUND MATERIAL. ADD TAG TO AVOID DAMAGE DURING TURNING.
1" QUICK CONNECT

COUPLING 7 COB INSULATION TO END HALFWAY AT 20 FT FROM HOT
1" CU SUPPLY INTAKE OF ZONE 3.
1" ISOLATOR W/ DRAIN VALVE
EXPANSION PRESSURE GAUGE
SWEAT CONN. BOTH SIDES ARDUINO CIRCUIT AND JUNCTION BOXES TO BE INSTALLED
8
1/8HP PUMP TANK ONTO 2X4" BOARDS SECURED VERTICALLY INTO GROUND.
SWEAT CONN. JUNCTION BOX TO TIE DIRECTLY TO NEAREST ELECTRICAL
PANEL.
9 COMPOST MOUND MATERIALS:

40 CU.YD. SHREDDED HARDWOOD MULCH
20 CU.YD. SAWDUST
SWEAT CONN. 5 CU.YD. MANURE
80 BALES OF STRAW FOR OUTER LINING
1" CU HW TO BEDS
90 DEG ELBOW QUICK
1/2" PEX Office for Sustainability
CONNECT 1" PEX Western Michigan University
1903 W Michigan Ave
1/2" PEX Kalamazoo, MI 49008
CW TO
MOUND CW FROM BEDS Kelsey Pitschel
(810) 599-2396
Project Number 15-0720.00

MANIFOLD 2-LINE DETAIL
1
1 1/2" = 1'-0" Date 7/20/2015
Drawn By KP
Checked By DK
Scale
P502
As indicated
COMPOST IN-MOUND SENSORS
CAP OPEN ENDS

CORN CRIB
M4 M1 HOBOWARE IN-MOUND
TEMP SENSOR X6
26
TL1
M5
M2
VERTICAL SENSORS
M3 2FT INTERVALS
ATTACH SENSORS THRU

PVC DRILLED HOLES COIL TOWER
13' - 6" COLD RETURN
HOT SUPPLY

C. Appendix C: Agrilab Feasibility Study
Agrilab Technologies, LLC
1662 Pumpkin Village Rd, Enosburg Falls, VT 05450
802.933.8336
www.agrilabtech.com aelan@agrilabtech.com
G

Feasibility Report and Design Recommendation for a CompostPowered Water Heating System for
Gibb’s Farm at Western Michigan University

Executive Summary :
Gaelan Brown, Founder of CompostPower.org, Author of The Compost Powered Water Heater , and
partner in Agrilab Technologies (AGT) believes that a compostpowered heating system using a
modified “Jean Pain Method” approach is an appropriate application for the greenhouse heating
needs of Gibb’s Farm at Western Michigan University, to provide hot water for a radiant seedbed
heating system in the Gibb’s Farm Greenhouse 1. The exact Btu needs to maintain water temperature
for radiant floor system are not specifically known by the client, and the Btu output of a modified Jean
Pain system is not perfectly predictable. However, we have experience using this method of compost
powered water heating systems for heating winter greenhouses of this size, and we have confidence
this can be a cost effective method for the desired results of producing approximately 10,000+
Btus/hr through a continual supply of 110F130F water which should meet the majority of the heating
needs identified.

As there are many variables that can enhance or impede energy performance, this should be seen as
an experiment with a range of heating output expectations and understanding that performance of
the system may not meet all of the hot water needs. The value of the finished compost from the
system approximately a year later should be seen as one of the primary return on investment factors
in terms of recovering the material cost of building the system.

We are confident that the size and approach outlined in this document has a very high likelihood of
being successful. In some of our previous Jean Pain style projects where the heat output did not meet
expectations the primary reasons included the system being too small (systems that were only 2030
cubic yards) to maintain critical thermal mass through the winter climates. In other systems that did
not perform to expectations the wrong feedstock was used such as rotresistant hemlock or there was
a lack of aeration or moisture in the feed stock. We have included modifications to the approach that
we believe will enable easy and efficient use of time and materials. Since the cost of building the
system can be kept to a minimum and you will have strong costrecovery from the use of the
compostproduct at the end of the cycle, AGT believes this is a viable approach and we look forward
to being associated with this project.

Fee due upon receipt of this report : $500 in exchange for Gaelan Brown’s time spent on scoping and
customizing, feedstock sourcing or recipe recommendations, needs assessment, and follow ups.

Any mailed correspondence and payments should be sent to: Gaelan Brown, Agrilab Technologies,
and mailed to PO Box 637, Waitsfield VT 05673, or emailed to gaelan@agrilabtech.com .

System parameters/goals:
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1. Heating output goal of 10,000 Btu/hr via hot water production in the temperature range of
110130 degrees F, to maintain water temperature for radiant floor/raised bed greenhouse
heating system zones.
2. Water circulation system design/installation is out of scope of this report but can be kept
simple and low cost by installing a simple circulation pump such as a Taco ¼ HP or 1/8 HP
pump to move water through the compost heat exchange loops with hot water returned into
the water tank(s) tied into an ondemand heater, or directly circulated into radiant heating
zones in the greenhouse.
3. Compostpowered heating system located next to the point of use as discussed to minimize
length of below grade insulated supply/return piperuns.
4. The size of the compost power system shall be approximately 60 cubic yards of compost feed
stock, with a circular system measuring 8ft tall by 16ft diameter; OR in a rectangular pile 6ft
high, 12ft wide by 20ft long, plus insulating sidewalls of stacked hay bales.
5. Incompost heat exchange options, rectangular modules or vertical columns :
a. Option 1: Six 4ft by 12ft cattlepanel fencing sections will be used to preaffix PEX
water lines with 150 feet of 1 inch or ¾ inch PEX tubing on each cattle panel. Each
module will be plumbed together as the system is built via a simple “manifold”. When
it’s time to tear down the mound, the modules can be disconnected and easily
dragged out of the compost material quickly and easily, and then reused on the next
project.
b. Option 2: Three heatexchange columns made of hardware cloth/chickenwire, each
wrapped in 300 feet of poly or pex tubing. This option requires more initial
construction time for the heatexchange columns, but is recommended for a number
or reasons as described below.

Recommended Compost Powered Hot Water System Design/System Parameters:
1. 60 cubic yards of the following recipe options for the feedstock:
a. 40 cubic yards of fresh wood chips from nonrotresistant species of wood;
b. 1520 cubic yards of fresh saw dust or millshavings from nonrotresistant species of
wood.
c. Up to five yards of fresh manure;
d. All materials must be thoroughly blended beforehand or during construction of the
system.
e. Absolute avoidance of all rotresistant wood species such as hemlock, cedar, black
locust, redwood, douglas fir.
f. Feedstock must be relatively fresh or from a drystorage facility.
g. Large amounts of water will be required to thoroughly soak the feedstock as the
system is built.
h. 80 hay or straw bales for structural insulating sidewalls.
2. Pex tubing for the incompost heat exchange loops and belowgrade supply/return lines:
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a. 900 feet of 1 inch or ¾ inch diameter PEX potablewater tubing for heat exchange
modules, purchased in 300 foot sections preferably. Pex tubing should cost around
$.40 per linear foot from plumbing supply stores.
b. Additional PEX tubing to connect the compost power mound to and from the water
tank in the building.
c. Couplings, connectors and ringclamps for the tubing (number of couplings depends
on the length of each section of tubing purchased.
d. Zip ties to attach tubing to heat exchange cattle panels or columns.
e. Pipe insulation and impermeable 2 inch or 4 inch conduit for the belowgrade
supply/return lines between the Compost Power system and the point of use: You
need enough pipe insulation and conduit to get from the compost power mound to
the water storage tank/building. Each run of insulated pipe will be inserted into a
conduit to prevent groundwater from getting near the pipes.
3. Incompost Heat Exchange Option 1 Description:
a. Six cattle panels each with 150 feet of PEX tubing in the compost, the first two panels
placed side by side after a 36 inch layer of mixed/soaked compost feedstock is spread
over the aeration tubing, with 12 inches of compost feedstock layered on top of each
subsequent heat exchange module layer and three total layers of heat exchange
modules.
b. Cattle panels can be purchased in 4ft wide by 12ft long or 16ft long sections.
http://www.homedepot.com/p/16ft4GaugeCattlePanels33150739/202820268
c. Use zip ties to affix 150ft of PEX tubing on each cattle panel as shown in pictures
below, with the beginning and end of the PEX tubing terminating in the same general
area on one end of the cattle panel.
d. Plumbing each cattlepanel module together in series: You can use “Push Connect”
fittings to connect the supply/return PEX lines of each cattle panel module together.
These fittings enable easy watertight connections without special tools required.
Crimp fittings are recommended to ensure no water leaks. A disconnect tool can later
be used to quickly disconnect the pushconnect lines when it’s time to tear down the
mound and rebuild the next one using the same fittings. If crimp connections are
used, couplings will need to be cut and discarded when mound is deconstructed. This
website below is a good source for these connections and the disconnection tool.
You’ll need 12 Push Connect fittings to combine the 6 cattle panel modules together,
plus 2 more to connect the supply/return lines to the water tank to the first heat
exchange module in the lower end of the mound.
http://www.pushconnect.com/plumbingproductsforpextubing.htm
e. Regular pex compressionconnection fittings can also be used to connect each each
cattle panel section of tubing, if desired, to ensure no water leaks. The annual tear
down process would then require cutting the pex fittings and then replacing the
couplings for reconnection, which is a minimal expense to incur. A professional
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plumber should be employed to ensure proper connections/fittings and water
circulation system components.
f. You’ll also need plumbing connection fittings to connect the supply and return water
lines to the water storage tank or radiant heating manifold in the building.

4. Option 2; Compost Heat Exchange Design with Vertical Columns : Build three preassembled
six feet tall columns of cylindrical shaped fencing material each wrapped with 300 feet of
polyethylene tubing with supply/return lines oriented at the top of each column.
a. This method of heat exchange “column arrays” enables faster construction and
deconstruction instead of gradually laying out poly tubing across several layers of
compost. This method is also better than the cattle panel heat exchanger method
which requires flexible connections between the manifolds to accommodate material
settling in between each layer.
b. Start with 20 feet of six foot tall hardware cloth or medium grade chicken wire.
c. Create three 6.5 foot long sections of chicken wire/hardware cloth from the 20ft long
section, and use wire or zipties to form them in cylindrical columns approximately 30
inches in diameter, six feet tall.
d. Starting at the top of each column, wrap the polyethylene tubing around the outside
of the column, affixing with zip ties, spacing each ring of tubing 1.5 inches from the
layer above it.
e. Once the coiled column is wrapped to the bottom, create several bottom to top loops
through the inside of the column and back up and around the outside, space
equidistant from each other until all but 6 feet of tubing is used up with the remaining
tubing loosely zip tied near the top. Save the last 6 feet of tubing returning up through
the center terminating near the beginning of the tubing.
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5. Sidewall Structure/Insulation/Moisture Retentions : we recommend using a stacked sidewall
of hay or straw bales around the compost power system to provide sidewall structure and
insulation/moisture retention value;
a. A system this size/shape would require 20 hay bales per layer, ideally with 4 to 6 layers to
contain the 6 to 8 ft height of the mound. Shown is a circular mound insulated with this
method for reference.

6. Circulator pumps :
a. A 1/8 HP circulator pump (Taco is a common and reliable brand) is sufficient to move
water from the storage tank through the compost heat exchange loops and back to
the storage tank. ¼ HP pump is likely not strong enough to handle this amount of
water line/circulation/head, but a competent plumber should be consulted to ensure
the right pump is used. The rate of circulation should be kept between one half gallon
per minute and 1.5 gallons per minute continuously once the system is running. If a
single pump is planned to be used to circulate through the compost heat exchange
zones as well as the radiant heating zones in the building, a larger pump may be
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required. A competent HVAC professional experienced in radiant floor heating
systems should be engaged to determine the right pump needed.

7. Simple Data Monitoring equipment options: Data capture tools already identified by the
project manager should be adequate. Other references/options are listed below.
a. The Btu capture data can be calculated if you know the circulation rate and the
temperature of the supply and return water to/from the compost heat exchange
loops. Monitoring the temp of the supply/return water lines on a daily basis can be
done manually and btu capture data can be compiled over time.
b. In line temperature sensor/thermometers on both the supply and return pipes
between the compost system and the water tank can be used to track temperature
performance and heatexchange value of the system as long as the circulation
flowrate is known. These temp gauges usually cost under $20 and can be purchased
at plumbing/HVAC supply stores or online at this link:
http://www.houseneeds.com/heating/hydronicheatsupplies/temperaturegaugesa
nalog
c. Here’s a low cost flow meter that could be plumbed into the water line next to the
circulation pump.
http://www.amazon.com/RAINWAVEWATERTIMERSAVEMETER/dp/B007NHS9M4/
ref=sr_1_1?ie=UTF8&qid=1395417411&sr=81&keywords=water+flow+meter
d. Compostprobe thermometers such as Reotemp can also be used to track
temperature of the composting material, and come in various lengths up to 6 feet. But
extreme care must be taken when inserting a probe into the compost to avoid
puncturing a heat exchange pipe. Here’s a link to Reo Temp compost thermometers
made in San Diego: http://www.reotemp.com/compostingproducts.html

8. Data Logger Recommended Options :
a. If a reliable ethernet/internet connection can be established and if robust remote data
monitoring is desired, we suggest using a Web Energy Logger. The prices can be found
at
www.welserver.com ; The advantage of the WEL is that you can gang several
sensors together on one logger (up to 50) – This is the most cost effective way we
know of to measure multiple temperature points with webbased logging. The two
weaknesses of the WEL are that it requires a reliable internet connection (when the
net goes down, you'll get a gap in the data), and that if the sensor bus shorts out
anywhere you lose all the data until you fix it. We are experienced at wiring and
waterproofing these systems which allows for quick troubleshooting and can offer
assistance configuring the data logger if needed.
b. For a noninternet approach, we recommend the HOBO 4channel data loggers.
http://www.onsetcomp.com/products/dataloggers/U12dataloggers
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i. We recommend the U12 for $113 (non weatherproof) or $226. The sensors
are expensive and costs add up quickly; you need the 20' sensor at $44 ea or
the 50' sensor at $50 each.
c. Sensor Placement: we recommend embedding a sensor on both the main
supply/return pipe from the compost heating system, and at least one sensor near
each heatexchange zone inside the compost.
9. Summary of Recommended Design Specifications and Elements:
a. One 60 cubic yard circular mound system approximately 16 feet wide and 8 feet tall,
plus the outer insulating hay bale side walls.
b. Aeration tubing : 100 feet of
4inch corrugated/perforated drainage pipe laid out in
an circular pattern on the ground after the first layer of hay bales is set in place to
define the perimeter. One end of the aeration pipe terminates in the center, the other
end extends through to the outside of the bale wall, between two of the bales.
Aeration pipe should be spaced evenly throughout the area, with the outer ring of
pipe kept 12 inches from the inside wall of the insulating hay bales.

c. Structural sidewalls/insulation: Use hay or straw bales when available. (old bales or
green/junk wet bales are good) Vertical sidewalls enable larger amounts of heat
exchange to happen higher in the material and create a consistent column of material
to enhance “chimney effect” of passive aeration while retaining moisture in the
compost feed stock. Your size system requires approximately 20 bales per layer with
4 layers of bales (80 bales total) to contain/insulate the system.
d. Maximum height of a Jean Pain style system should not exceed 18 feet to avoid risk of
spontaneous combustion from too much chimney effect. This design has a height of
approximately 8 feet.
e. Heat Exchange Zones in Compost Power mound :
i. Option 1: Six cattle panels each with 150 feet of PEX tubing in the compost,
the first two panels placed side by side after a 36 inch layer of mixed/soaked
compost feedstock is spread over the aeration tubing, with 12 inches of
compost feedstock layered on top of each subsequent heat exchange module
layer and three total layers of heat exchange modules.
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ii. Option 2: Three 6ft tall 30 inch diameter vertical chickenwire columns each
wrapped with 300 feet of tubing.
10. Step by step construction directions: (see images below showing stages of each
approach/step)
1. Dig a 12 inch deep 1016 inch wide trench from the location of the point of use in the
building to edge of where the compost power mound will be located, for the insulated
supply/return water lines. Well insulated supply/return water lines are critical to winter
operation.
2. Measure/cut two lengths of PEX tubing for the supply/return lines. Slide pipe insulation on
each. Leave at least 10 extra feet of PEX tubing for both the supply and return lines,
extending from the end of the trench on the end where the compost power mound will be
built. These will later be connected to the compost heat exchange modules/manifold.
3. On each end of each pipe in the trench mark one pipe “hot supply” and the other “cold
return” with ducttape/markers.
4. Lay each section of insulated/conduit pipe in the trench. Be sure to have at least 10 feet of
excess pipe for the cold water return pipe extending from the trench through where the
hay bale wall will be. Make sure the hotwater supply pipe extends from the compost end
of the trench at least 10 feet through where the bale wall will be. This pipe will be
plumbed to the manifold connections that will tie into each zone of the cattle panel heat
exchange loops during the final stage of construction.

5. Run any sensor wires for inmound sensors next to the pipe conduits and into the center
of where the mound will be built, laying the compost end of any sensor wires to the side
temporarily (later to be embedded in the compost).
6. Cover the insulated conduit/pipe/wires with dirt, filling the trench.
7. Lay out the first course of hay bales to mark the perimeter of the system, with the
intrench supply/return pipes extending inside the bale wall. Make sure the cold water
supply and hot water return lines extend from the trench into the inside perimeter of the
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bale wall near the end where the zones will be manifolded together, but also make sure
the ends of each pipe are then set aside so they will not be inadvertently buried in
compost as the mound is built.
8. Lay out 100 feet of perforated 4 inch flexible aeration tubing in oblong evenlyspaced
loops on the ground inside the bale wall, with one end terminating in the center, the
other terminating slightly outside of the bale wall perimeter.

9. Cover the perforated tubing with a 12 inch layer of compost feedstock as the material is
thoroughly soaked to saturation point with water and spread out evenly.
10. Lay out the 2nd
course of hay bale side walls in a brickstyle overlap pattern on top of the
first course, with bales offset inward toward the center about 12 inches compared to the
first course of bales. (this will help ensure the bale wall leans slightly inward toward the
compost, preventing the bales from potentially collapsing outward).
11. Spread another 1218 inch layer of mixed/soaked compost feed stock until material is at
the height of the 2nd course of bales with at 24 to 30 inch high layer of compost feed stock
on top of the contained by the first 2 courses of hay bales.
12. Heat Exchange Module placement:
a. If using Option 2, vertical columns:
i. Place the three vertical columns in the center of the mound area, spaced
12 inches apart from each other.
ii. Connect the main cold water return line from the trench to a 3way
manifold which will split the water flow evenly to each of the 3 heat
exchange columns.
iii. Connect the main hot water supply line from the trench to a 3way
manifold which will split the hot water flow evenly from each of the 3 heat
exchange columns.
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iv. Connect the three coldwater supply manifold fittings to each of the
coldwatersupply lines on each heat exchange column.
v. Connect the three hotwater return manifold fittings to each of the hot
water return lines on each heat exchange column.
vi. Gradually add well mixed and thoroughly soaked compost feed stock
around the outside of the 3 heat exchange columns, adding additional
layers of hay bales to contain the material while making slightly inward
sloping sidewalls of the mound with the hay bales.
vii. Fill in the interior of each heat exchange column with well mixed/soaked
compost feedstock.
viii. Once the top of the columns is covered in compost feed stock, add an
additional 18+ inches of compost feedstock to cap the pile.
ix. Cover the top of the mound with an 812 inch layer of loose hay. Soak the
hay on top with additional water for 20 minutes. Mound construction is
now complete.
b. If Using Cattle Panel Heat Exchange Modules:
i. Set the first two HE cattle panel modules side by side on top of the
compost feed stock, you should have approximately 1218 inches of open
space between the outside edge of the cattle panels and the
inside
of the
bale wall.
ii. Lay out the 4th course of hay bale walls.
iii. Connect the cold water supply line from the trench into one water line of
one of the cattle panel HE modules. Connect the other end of the PEX
tubing on that same cattle panel to one of the PEX lines of the 2nd
cattle
panel.
iv. Connect a 36 inch section of PEX tubing from the remaining PEX line on

the 2nd cattle panel and set that PEX connector line aside with the end
temporarily extending outside of the bale wall. This line will later be
connected to the 2nd
course of heat exchange modules.
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v. Cover the cattle panels with a 12 inch layer of soaked compost feedstock.

th
vi. Lay out the 4 layer of hay bales, remembering to ensure they are set in
place an inch or two inward so they lean in toward the compost.

vii. Lay the 2nd course of cattle panels and repeat steps 1217 until you have
rd
the 3 layer of cattle panels in place.
viii. Connect the hot water return PEX tubing from the trench to the remaining

PEX line available from the 3rd layer of cattlepanel heat exchange
modules. This will bring hot water from the compost heat exchange loops
back to your point of use.
rd
ix. Cover the 3 layer of heat exchange modules with a 24 inch layer of
soaked compost feedstock.
x. Cover the top of the mound with an 812 inch layer of loose packed hay,
as insulating and moisturecapturing material.
xi. Construction is now complete. All that remains is to fill the heat exchange
loops with water (ensuring that all air is pushed out of the lines), and to
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connect the supply/return water lines from the trench to your water tank
while installing the thermo couples on each line as well as the circulation
pump and flow meter. You’ll want a competent plumber to help with this
final stage of the construction.
Plumbing and operational overview:
1. Mount circulator pump to the cold water supply to the compost on the lower end of the
tank..
2. Attach the cold water supply to a bung hole in the low side of the tank. This will pull cooler
water out of the bottom of the water tank into the compost heat exchange loops
3. Mount data logger and/or thermocouples on supply/return pipes, if applicable, near the
tank and affix data logger sensor wires/etc.
4. Fill the system with water, ensuring that the fill/bleed valve allows all air to be pushed out
of the system as the hot water supply is connected to the top of the tank.
5. During the first two weeks after system is built, monitor the temperature readouts.
Compost material temperature should be between 120 and 150 degrees F within that
time. Once temperatures in that range have been achieved, activate circulation pump(s)
from the compost heating loop into the tank, at a flow rate of approximately ½ to 1 gallon
per minute. (partially close a valve on the circulation line until flow meter shows that
circulation raterange).
6. Monitor the temperature of sensors/thermometers daily during the first two weeks of
circulation being active. Once the compost temperatures are above 120F, you should be
able to maintain a circulation rate of between 1 gallon and 2 gallons per minute if the
water in the cold water line returning to the compost is above 70 degrees. If mound
temperature drops suddenly at any time, (which could be due to the radiant heating
system drawing too much heat out of the tank and thereby sending too much cold water
into the compost at too high of a circulation rate) reduce the circulation of the radiant
heating side of the system until mound temperature stabilizes in the range of 110140 F.
7. Use a ReoTemp compost thermometer probe (a 24 inch or 36 inch probe is best), or
electronic temp sensors to track temps of the inner core of the material. Be very careful
pushing the temp probe into the material, PEX/poly tubing becomes soft and flexible
when hot and punctures easily.
8. Monitor humidity of the compost feedstock with a humidistat probe, adding water back
onto the top of the compost feed stock with a sprinkler if internal humidity ever drops
below 45%.
http://www.benmeadows.com/oaktontemplogtemperatureandhumidityrhdatalogger
s_36817363/?searchterm=humidity

11. Operational Advice :
a. Since the actual heating load/exchange into the bath house will vary depending on
environmental factors and unknowns relative to the amount of hot water used, it will
be necessary to monitor and potential adjust the flow rate through both sides of the
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system and to monitor the temperatures of the hot water produced and temperatures
of the compost mass.
b. If the temperature of the hot water output water line is within 5 degrees of the peak
temp readout from sensors or temp probe inside the compost, you can pull more heat
out of the compost. Increase circulation through the mound by 10 to 20% and monitor
temperature data. If the temperature of the compost mass or the hot water supply to
the radiant system at any time shows a steady downward trend, reduce the flowrate
of both sides of the system by 20% per day until the output temperature stabilizes.
c. To determine circulation flow rate for a pump that does not have predetermined
circulation speeds, it may be necessary to use a voltage meter on the pump. This is not
necessary if you install a flow meter on the water lines. Refer to operator’s manual of
circulation pump for this method of determining flow rate. Circulation can be adjusted
by partially closing the valve on the cold water supply line, restricting flow.
d. The compost microbial ecology is averse to severe changes in flowrates or dramatic
intermittency of circulation, as this may shock the microbes causing a temporary
stalling of their culture. If at any time severe temperature drops in the compost mass
or hot water output are noticed, we recommend temporarily stopping circulation for
48 hours, check humidity of the compost material, and then restarting circulation at a
lower flow rate, gradually increasing flow until output temperature stabilizes.
e. If the compost mass for some reason dries out, the microbes will go into hibernation
and temperatures will drop. If this happens, place a sprinkler (warm water preferably)
on top of the mound and let a slow trickle of sprinkler water saturate the mound for
46 hours. Use warm water if possible, especially if this happens during winter
months.

Other Services Available: AGT would be happy to provide assistance on construction of the system as
well as integration of the monitoring/datalogger equipment. We can provide more detailed proposals
for these services upon request. Additional images from other projects are included below for
reference.

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D. Appendix D: Monthly Temperature Drop Plots
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E. Appendix E: Monthly Mound Vertical Temperature Plots
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F. Appendix F: Monthly Mound Horizontal Temperature Plots
52

G. Appendix G: Monthly Grow Bed Temperature, Head
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H. Appendix H: Monthly Grow Bed Temperature, Foot
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I. Appendix I: Manifold Shop Drawing
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Keywords: ​compost heat recovery, compost powered water heater, hoop house winter heating, closed loop system, winter

II. Table of Contents

IV. Best Practice Review

The design of the compost mound took place during the Fall of 2014 and the Spring of 2015. WMU Student Sustainability

W, work done by motor 318 Btu/hr State 2

Q, thermal energy rate, expected 10,000 Btu/hr Enthalpy 58.74 Btu/lbm

m, mass flow rate 0.06852 lbm/s Temperature 90F, avg

tubing that spanned the trench was wrapped in ½” foam insulation tubing, and sealed in aluminum foil tape. Once properly

C. Data Collection Methods

VIII. Limitations and Recommendations

IX. List of Contacts

Contact / Resource Resource Information

Woodham Farms Manure 35480 675th Ave, Portage, MI

Aaron Dykstra Wood chips and sawdust WMU Landscape Services

Andy Gene Sawdust P. (269) 373­5455

Josh Shultz System design consulting joshkhan2001@gmail.com

B. Appendix B: Mound Sensor Locations

C. Appendix C: AgriLab Feasibility Study

1 ALL CONSTRUCTION SHALL BE IN ACCORDANCE WITH

8 PUMP SHALL BE BASED ON 1/8-HP TACO 009-F5 OFFICE FOR

2 RIGID POLYMER FOAM BOARD TO SERVE AS INSULATION

Office for Sustainability

Project Number 15-0720.00

3 (7) SOIL TEMPERATURE - LOCATIONS AS SHOWN. INSTALL

PUMP SIZING CALCULATIONS 3 RADIANT LINES TO AND FROM VERMICOMPOST BIN TO BE

1" QUICK CONNECT

9 COMPOST MOUND MATERIALS:

Project Number 15-0720.00

CAP OPEN ENDS

ATTACH SENSORS THRU

13' - 6" COLD RETURN

D. Appendix D: Monthly Temperature Drop Plots

E. Appendix E: Monthly Mound Vertical Temperature Plots

F. Appendix F: Monthly Mound Horizontal Temperature Plots

G. Appendix G: Monthly Grow Bed Temperature, Head

H. Appendix H: Monthly Grow Bed Temperature, Foot

I. Appendix I: Manifold Shop Drawing

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Keywords: compost heat recovery, compost powered water heater, hoop house winter heating, closed loop system, winter

Andy Gene Sawdust P. (269) 3735455