Shape calibration of high strength metal sheets by electromagnetic forming

Electromagnetic (EM) forming is an emerging technique that is gaining acceptance for its complementary benefits to conventional metal forming techniques. In this work an innovative application of this impulse forming technique has been demonstrated: the EM shape calibration and correction of springback (sidewall curl) of DP600 and TRIP700 high strength steel (HSS) workpieces. This method has been applied as a second corrective step to previously deep drawn U-channels. The experimental results confirm the sidewall curl angle correction, achieving them with a 22 kJ discharge for DP600 samples and 24 kJ for TRIP700.On the other hand, an uncoupled multiphysical simulation strategy has been carried out in order to virtually validate the EM shape calibration method. The EM fields were simulated by Maxwell 3D and then the Pamstamp code was used to obtain the deformation process.     

Energy based phenomenological model for optimizing the sheared edge in the trimming of steels

Attributes related to the dimensional quality of hot rolled steels are very important in commercial sectors that make direct use of this product, because delay or equipment damage can be avoided when forming in downstream operations. In this research, the steel sheet edge trimming process and its relationship with the defect known as broken edge is experimental and numerically studied. The type of material, horizontal clearance between knives and the energy spent during the cutting process are analyzed in detail. A metal-mechanical study is carried out for obtaining a microstructural hardness and flow stress characterization. Consequently, the edge trimming process is FEM simulated and its results in relation to knife penetration and shear stress lead to determining the energy spent during the cutting process. A mathematical model is determined under the consideration that minimum energy gives the optimum cutting conditions. The model proposes a reliable value for the horizontal clearance (H_c), between knives, taking as the principal factors: energy consumed during the edge trimming process, sheet thickness (T_h), carbon content (C) and/or its ultimate tensile strength, expressed as: H_c = α + βT_h − γC. A comparison of the recommended numerical results with the best practical conditions is carried out and a high coincidence is successfully found. This model is expected to be easily adopted as a tool where operators can adjust and control the parameters of process, and then, as a result, produce a sheet without edge trimming defects as well as a reduction in efficiency costs.     

The development of a microscale strain measurement system applied to sheet bulge hydroforming

Micro and multiscale sheet metal forming processes represent new and attractive solutions to many manufacturing problems. However, evaluating the strains in these products is a difficult endeavor. Larger organizations are utilizing commercially available microscale digital image correlation systems to measure the strains in microscale parts or on macroscale parts with critical microscale features. The cost of these strain measurement systems is preventing smaller research and development organizations from entering this challenging area or they are forgoing the ability to determine strains. The present paper describes the development of a method for creating microscale grids and measuring strains on microscale parts or microscale locations on larger parts. The method developed was able to measure true strains up to 0.618 for square grids that are 127 μm measured from center-to-center. Microscale strains resulting from sheet bulge hydroforming experiments using 11 mm, 5 mm, and 1 mm diameter dies were evaluated and material properties of the sheet metal were estimated based upon the strains measured in conjunction with FEA simulations and compared to analytical solutions and microscale tension tests. The material properties determined using the strains and FEM approach were consistent with the other methods.     

Application of CGP-cross route process for microstructure refinement and mechanical properties improvement in steel sheets

A modified method of severe plastic deformation (SPD) entitled constrained groove pressing-cross route (CGP-CR) was introduced for imposing a high magnitude of equivalent strain of about 2.32 per pass on the sheet form samples. The major benefit of this improved route compared to previous common route was the more homogeneity of strain in the rolling (RD) and transverse (TD) directions of sheets. In this study, low carbon steel samples were used for examination of evolutions in microstructure and mechanical properties during SPD via CGP-CR process. Mechanical properties improvement were measured by tensile and macro hardness tests. The results indicate that CGP-CR process can effectively improve tensile strength; and also, yield stress and hardness of as-received low carbon steel samples were improved up to about 100% after two deformation passes. Also, high magnitude of inhomogeneity can be observed in hardness distribution through first pass of the process which diminishes in the subsequent passes. Microstructural evolutions during process were monitored by optical microscopy observations and X-ray diffraction analysis. The results demonstrate that initial ferritic microstructure with grain size of about 30 μm was refined to a 225 nm cell structure after two passes of CGP-CR process.     

A Study of the Optimization of Sheet Metal Drawing with Active Drawbeads

An experimental study is described in which active drawbead technology is used to attempt to optimize the sheet metal forming process. Oval AA 6111-T4 panels were drawn in a series of tests using various drawbead trajectories to establish the feasibility of the approach. The selection of drawbead trajectory was shown to have a dramatic effect on maximum attainable draw depth at fracture. Increasing drawbead penetration from zero to 5 mm in the early stages of the drawing process and retracting midway through the draw resulted in a 40% increase in draw depth compared to using a fixed 5 mm penetration. In the second part of the investigation, active drawbead technology was used to study its effect on highly nonsymmetric panel forming. Drawing limit curves in terms of drawbead depth versus blankholder forces (BHF) were plotted, and different drawbead trajectories were tested to determine an optimal drawbead trajectory scheme. A corresponding finite element model was also created. The results of strain path analysis successfully support the experiments.     

Exceedance of modern ‘background’ fine-grained sediment delivery to rivers due to current agricultural land use and uptake of water pollution mitigation options across England and Wales

Excessive loss of fine-grained sediment to rivers is widely recognised as a global environmental problem. To address this issue, policy teams and catchment managers require an estimate of the ‘gap’ requiring remediation, as represented by the excess above ‘background’ losses. Accordingly, recent work has estimated the exceedance of modern ‘background’ sediment delivery to rivers at national scale across England and Wales due to (i) current agricultural land cover, cropping and stocking, and (ii) current land use corrected for the uptake of on-farm mitigation measures. This sectoral focus recognises that, nationally, agriculture has been identified as the principal source of fine sediment loss to the aquatic environment. Two estimates of modern ‘background’ sediment loss, based on paleolimnological evidence, were used in the analysis; the target modern ‘background’ (TMBSDR) and maximum modern ‘background’ (MMBSDR) sediment delivery to rivers. For individual (n = 4485) non-coastal water bodies, the sediment ‘gap’ in excess of TMBSDR and MMBSDR, due to current land cover, cropping and stocking, was estimated to range up to 1368 kg ha⁻¹ yr⁻¹ (median 61 kg ha⁻¹ yr⁻¹) and 1321 kg ha⁻¹ yr⁻¹ (median 19 kg ha⁻¹ yr⁻¹), respectively. The respective ranges in conjunction with current land cover, cropping and stocking but corrected for the potential impact of on-farm sediment mitigation measures were up to 1315 kg ha⁻¹ yr⁻¹ (median 50 kg ha⁻¹ yr⁻¹) and 1269 kg ha⁻¹ yr⁻¹ (median 8 kg ha⁻¹ yr⁻¹). Multiplication of the estimates of excess sediment loss corrected for current measure uptake, above TMBSDR and MMBSDR, with estimated maximum unit damage costs for the detrimental impacts of sediment pollution on ecosystem goods and services, suggested respective water body ranges up to 495 £ ha⁻¹ yr⁻¹ and 478 £ ha⁻¹ yr⁻¹. Nationally, the total loss of sediment in excess of TMBSDR was estimated at 1,389,818 t yr⁻¹ equating to maximum environmental damage costs of £523 M yr⁻¹, due to current structural land use, compared to 1,225,440 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹ due the uptake of on-farm sediment control measures. The corresponding total loss of sediment in excess of MMBSDR was estimated at 1,038,764 t yr⁻¹ equating to maximum damage costs of £462 M yr⁻¹, compared with 890,146 t yr⁻¹ and £335 M yr⁻¹ correcting excess agricultural sediment loss for current implementation of abatement measures supported by policy instruments. This work suggests that the current uptake of sediment control measures on farms across England and Wales is delivering limited benefits in terms of reducing loadings to rivers and associated environmental damage costs.     

Effect of quasi-static prestrain on the formability of dual phase steels in electrohydraulic forming

Dual phase steels derive their name from their microstructure, which consists of islands of martensite surrounded by a ferrite matrix. These steels are increasingly being used in automobile structures in order to reduce weight, improve fuel economy, and maintain crash safety performance. The higher strength grades of dual phase steels, such as DP780 and DP980, often present significant formability challenges in sheet stamping operations, and therefore any technologies which could alleviate these issues would be of significant value to the automotive industry. Electrohydraulic forming (EHF) is based upon the electro-hydraulic effect: a complex phenomenon related to the discharge of high voltage electrical current through a liquid. In EHF, electrical energy is stored in a bank of capacitors and is converted into the kinetic energy needed to form sheet metal by rapidly discharging that energy across a pair of electrodes submerged in a fluid. During such a discharge, a high pressure, high temperature plasma channel is created between the tips of the electrodes. The resulting shockwave in the liquid, initiated by the expansion of the plasma channel, is propagated toward the blank at the acoustic velocity of the fluid, and the mass and momentum of the water in the shock wave accelerates the sheet metal blank toward the die. The objective of this paper is to report the results of formability testing of dual phase steels under three basic conditions: (1) conventional limiting dome height (LDH) testing; (2) starting with a flat blank and using one pulse of EHF to fill the desired die geometry; and (3) starting with a quasi-static preforming step to partially fill the die cavity and then using one pulse of EHF to fill the remaining area of the die cavity. A hybrid process which combines sheet hydroforming (HF) and EHF as described herein has the potential to reduce the cycle time of the EHF process by replacing the initial EHF forming increments with one quasi-static preforming step. Additionally, a numerical model was developed and employed in order to better understand the sheet deformation process within EHF. The numerical model consists of four distinct models that are integrated into one: (1) an electrical model of the discharge channel, (2) a model of the plasma, (3) a model of the liquid as a pressure-transmitting medium, and (4) a deformable sheet metal blank in contact with a rigid die. Significant improvements in formability were confirmed experimentally for DP780 and DP980 by forming into conical and v-shape dies using EHF from a flat sheet and by using EHF combined with a quasi-static preforming step. Numerical modeling showed that the peak strain rates occurring in both single-pulse EHF the hybrid HF-EHF process are approximately 17,000 units per second.     

Soil-profile organic carbon and total nitrogen during 12 years of pasture management in the Southern Piedmont USA

Soil organic C (SOC) and total soil N (TSN) sequestration estimates are needed to improve our understanding of management influences on soil fertility and terrestrial C cycling related to greenhouse gas emission. We evaluated the factorial combination of nutrient source (inorganic, mixed inorganic and organic, and organic as broiler litter) and forage utilization (unharvested, low and high cattle grazing pressure, and hayed monthly) on soil-profile distribution (0–150 cm) of SOC and TSN during 12 years of pasture management on a Typic Kanhapludult (Acrisol) in Georgia, USA. Nutrient source rarely affected SOC and TSN in the soil profile, despite addition of 73.6 Mg ha^?1 (dry weight) of broiler litter during 12 years of treatment. At the end of 12 years, contents of SOC and TSN at a depth of 0–90 cm under haying were only 82 ± 5% (mean ± S.D. among treatments) of those under grazed management. Within grazed pastures, contents of SOC and TSN at a depth of 0–90 cm were greatest within 5 m of shade and water sources and only 83 ± 7% of maximum at a distance of 30 m and 92 ± 14% of maximum at a distance of 80 m, suggesting a zone of enrichment within pastures due to animal behavior. During 12 years, the annual rate of change in SOC (0–90 cm) followed the order: low grazing pressure (1.17 Mg C ha^?1 year^?1) > unharvested (0.64 Mg C ha^?1 year^?1) = high grazing pressure (0.51 Mg C ha^?1 year^?1) > hayed (?0.22 Mg C ha^?1 year^?1). This study demonstrated that surface accumulation of SOC and TSN occurred, but that increased variability and loss of SOC with depth reduced the significance of surface effects.     

Influence of displacement constraints in thermomechanical analysis of laser micro-spot welding process

The evolution of mechanical components into smaller size generating a need for microwelding of these components using laser which offers better control as compared to arc and plasma processing. The present article describes the numerical simulation of laser micro-spot welding using finite element method. A two dimensional Gaussian distributed surface heat flux as a function of time is used to perform a sequentially coupled thermal and mechanical analysis. The model is used for simulating laser micro-spot welding of stainless steel sheet under different power conditions and configurations of mechanical constraints. The temperature dependent physical properties of SS304 have been considered for the simulation and an isotropic strain hardening model has been used. The simulated weld bead dimensions have been compared with experimental results and temperature profiles have been calculated. The maximum deformation of 0.02 mm is obtained with maximum laser power of 75 W. The thermal stress is more inducing factor to temperature induced residual stresses and plastic strain as compared to mechanical constraints. The plastic strain changes significantly by displacement constraints as compared to residual stress.     

Long-term impact of a gliricidia-maize intercropping system on carbon sequestration in southern Malawi

Tree/crop systems under agroforestry practice are capable of sequestering carbon (C) in the standing biomass and soil. Although studies have been conducted to understand soil organic C increases in some agroforestry technologies, little is known about C sequestered in simultaneous tree/crop intercropping systems. The main objective of this study was to determine the effect of agroforestry practice on C sequestration and CO₂-C efflux in a gliricidia-maize intercropping system. The experiment was conducted at an experimental site located at the Makoka Agricultural Research Station, in Malawi. The studies involved two field plots, 7-year (MZ21) and 10-year (MZ12), two production systems (sole-maize and gliricidia-maize simultaneous intercropping systems). A 7-year-old grass fallow (Grass-F) was also included. Gliricidia prunings were incorporated at each time of tree pruning in the gliricidia-maize. The amount of organic C recycled varied from 0.8 to 4.8 Mg C ha⁻¹ in gliricidia-maize and from 0.4 to 1.0 Mg C ha⁻¹ in sole-maize. In sole-maize, net decreases of soil carbon of 6 Mg C ha⁻¹ at MZ12 and 7 Mg C ha⁻¹ at MZ21 in the topsoil (0–20 cm) relative to the initial soil C were observed. After 10 years of continuous application of tree prunings C was sequestered in the topsoil (0–20 cm) in gliricidia-maize was 1.6 times more than in sole-maize. A total of 123–149 Mg C ha⁻¹ were sequestered in the soil (0–200 cm depth), through root turnover and pruning application in the gliricidia-maize system. Carbon dioxide evolution varied from 10 to 28 kg ha⁻¹ day⁻¹ in sole-maize and 23 to 83 kg ha⁻¹ day⁻¹ in gliricidia-maize. We concluded that gliricidia-maize intercropping system could sequester more C in the soil than sole-maize.     

Carbon footprint of sugar produced from sugarcane in eastern Thailand

Carbon footprint (CFP) of sugar produced from sugarcane in eastern Thailand was estimated from greenhouse gas emissions (CO₂, CH₄, and N₂O) during the sugarcane cultivation and milling process. The use of fossil fuels, chemical and organic fertilizer and sugarcane biomass data during cultivation were collected from field surveys, questionnaires and interviews. Sugar mill emissions, fossil fuel utilization and greenhouse gas emission from wastewater treatments were included. The results show that sugar production has a carbon footprint of 0.55 kg CO₂e kg^?1 sugar. This carbon footprint was a sum of 0.49 kg CO₂e kg^?1 sugar from sugarcane cultivation and 0.06 kg CO₂e kg^?1 sugar from the milling process. For the cultivation part, most of the GHGs emissions were from fertilizer, fossil fuel use and biomass burning. The CFP in eastern Thailand is sensitive to the type of data selected for calculation and of variations of farm inputs during sugarcane cultivation. There was no significant difference of CFP among farm sizes, although small farms tended to give a relatively higher CFP than that of medium and large farms.     

Investigation on mechanism of phosphate removal on carbonized sludge adsorbent

For the removal of phosphate (PO₄^3 -) from water, an adsorbent was prepared via carbonization of sewage sludge from a wastewater treatment plant: carbonized sludge adsorbent (CSA). The mechanism of phosphate removal was determined after studying the structure and chemical properties of the CSA and its influence on phosphate removal. The results demonstrate that phosphate adsorption by the CSA can be fitted with the pseudo second-order kinetics and Langmuir isotherm models, indicating that the adsorption is single molecular layer adsorption dominated by chemical reaction. The active sites binding phosphate on the surface are composed of mineral particles containing Si/Ca/Al/Fe. The mineral containing Ca, calcite, is the main factor responsible for phosphate removal. The phosphate removal mechanism is a complex process including crystallization via the interaction between Ca^2 + and PO₄^3 -; formation of precipitates of Ca^2 +, Al^3 +, and PO₄^3 -; and adsorption of PO₄^3 - on some recalcitrant oxides composed of Si/Al/Fe.     

The water footprint of food waste: case study of fresh mango in Australia

In many parts of the world, freshwater is already a scarce and overexploited natural resource, raising concerns about global food security and damage to freshwater ecosystems. This situation is expected to intensify with the FAO estimating that world food production must double by 2050. Food chains must therefore become much more efficient in terms of consumptive water use. For the small and geographically well-defined Australian mango industry, having an average annual production of 44,692 t of marketable fresh fruit, the average virtual water content (sum of green, blue and gray water) at orchard gate was 2298 l kg^?1. However, due to wastage in the distribution and consumption stages of the product life cycle, the average virtual water content of 1 kg of Australian-grown fresh mango consumed by an Australian household was 5218 l. This latter figure compares to an Australian-equivalent water footprint of 217 l kg^?1, which is the volume of direct water use in Australia having an equivalent potential to contribute to water scarcity. Nationally, distribution and consumption waste in the food chain of Australian-grown fresh mango to Australian households represented an annual waste of 26.7 Gl of green water and 16.6 Gl of blue water. These findings suggest that interventions to reduce food chain waste will likely have as great or even greater impact on freshwater resource availability as other water use efficiency measures in agriculture and food production.     

Nutrient flows in small-scale peri-urban vegetable farming systems in Southeast Asia—A case study in Hanoi

In many peri-urban areas of Southeast Asia, land use has been transformed from rice-based to more profitable vegetable-based systems in order to meet the increasing market demand. The major management related flows of nitrogen (N), phosphorus (P), potassium (K), copper (Cu) and zinc (Zn) were quantified over a 1-year period for intensive small-scale aquatic and terrestrial vegetable systems situated in two peri-urban areas of Hanoi City, Vietnam. The two areas have different sources of irrigation water; wastewater from Hanoi City and water from the Red River upstream of Hanoi. The first nutrient balances for this region and farming systems are presented. The main sources of individual elements were quantified and the nutrient use efficiency estimated. The environmental risks for losses and/or soil accumulation were also assessed and discussed in relation to long-term sustainability and health aspects.The primary source of nutrient input involved a combination of chemical fertilisers, manure (chicken) and irrigation water. A variable composition and availability of the latter two sources greatly influenced the relative magnitude of the final total loads for individual elements. Despite relatively good nutrient use efficiencies being demonstrated for N (46–86%) and K (66–94%), and to some extent also for P (19–46%), high inputs still resulted in substantial annual surpluses causing risks for losses to surface and ground waters. The surplus for N ranged from 85 to 882 kg ha⁻¹ year⁻¹, compared to P and K which were 109–196 and 20–306 kg ha⁻¹ year⁻¹, respectively. Those for Cu and Zn varied from 0.2 to 2.7 and from 0.6 to 7.7 kg ha⁻¹ year⁻¹, respectively, indicating high risk for soil accumulation and associated transfers through the food chain.Wastewater irrigation contributed to high inputs, and excess use of organic and chemical fertilisers represent a major threat to the soil and water environment. Management options that improve nutrient use efficiency represent an important objective that will help reduce annual surpluses. A sustainable reuse of wastewater for irrigation in peri-urban farming systems can contribute significantly to the nutrient supply (assuming low concentrations of potential toxic or hazardous substances in the water). Nutrient inputs need to be better related to the crop need, e.g. through better knowledge about the nutrient concentrations in the wastewater and improved management of the amount of irrigation water being applied.     

Dairy farm CH4 and N2O emissions,from one square metre to the full farm scale

The greenhouse gas emissions from agricultural systems contribute significantly to the national budgets for most countries in Europe. Measurement techniques that can identify and quantify emissions are essential in order to improve the selection process of emission reduction options and to enable quantification of the effect of such options. Fast box emission measurements and mobile plume measurements were used to evaluate greenhouse gas emissions from farm sites. The box measurement technique was used to evaluate emissions from farmyard manure and several other potential source areas within the farm. Significant (up to 250 g CH₄ m⁻² day⁻¹and 0.4 g N₂O m⁻² day⁻¹) emissions from ditches close to stables on the farm site were found.Plume emission measurements from individual manure storages were performed at three sites. For a manure storage with 1200 m³ dairy slurry in Wageningen emission factors of 11 ± 5 g CH₄ m⁻³ manure day⁻¹ and 14 ± 8 mg N₂O m⁻³ manure day⁻¹ were obtained in February 2002.Mobile plume measurements were carried out during 4 days at distances between 30 and 300 m downwind of 20 different farms. Total farm emissions levels ranged from 14 to 95 kg CH₄ day⁻¹ for these sites. Expressed as emission per animal the levels were 0.7 ± 0.4 kg CH₄ animal⁻¹ day⁻¹ for conventional farms. For three farms that used straw bedding for the animals1.4 ± 0.2 kg CH₄ animal⁻¹ day⁻¹ was obtained. These factors include both respired methane and emission from manure in the stable and the outside storages.For a subset of these farms the CH₄ emission was compared with monthly averaged model emission calculations using FarmGHG. This model calculates imports, exports and flows of all products through the internal chains on the farm using daily time steps. The fit of modelled versus measured data has a slope of 0.97 but r² = 0.27. Measurements and model emission estimates agree well on average, for large farms within 30%. For small farms the differences can be up to a factor of 3. CH₄ emissions during winter seem to be underestimated.     

Integrated environmental assessment of biodiesel production from soybean in Brazil

This paper presents the results of an environmental impact assessment of biodiesel production from soybean in Brazil. In order to achieve this objective, environmental impact indicators provided by Emergy Accounting (EA), Embodied Energy Analysis (EEA) and Material Flow Accounting (MFA) were used. The results showed that for one liter of biodiesel 8.8 kg of topsoil are lost in erosion, besides the cost of 0.2 kg of fertilizers, about 5.2 m² of crop area, 7.33 kg of abiotic materials, 9.0 tons of water and 0.66 kg of air and about 0.86 kg of CO₂ were released. About 0.27 kg of crude oil equivalent is required as inputs to produce one liter of biodiesel, which means an energy return of 2.48 J of biodiesel per Joule of fossil fuel invested. The transformity of biodiesel (3.90E + 05 seJ J^?1) is higher than those calculated for fossil fuels as other biofuels, indicating a higher demand for direct and indirect environmental support. Similarly, the biodiesel emergy yield ratio (1.62) indicates that a very low net emergy is delivered to consumers, compared to alternatives. Obtained results show that when crop production and industrial conversion to fuel are supported by fossil fuels in the form of chemicals, goods, and process energy, the fraction of fuel that can actually be considered renewable is very low (around 31%).     

On wear resistance of tool steel

Maintaining a reasonably low cutting tool wear when producing forming tools is a general challenge in the development of new forming tool materials. The tool life of a hot forming tool steel (H13) has been significantly improved by reducing its Si-content from 1.0 to 0.06 wt.%. However, this modified H13 (MH13) also displays a reduced cutting tool life due to higher cutting forces and a stronger tendency to form built up layers (BUE) on the cutting edge. This paper explains why.Gleeble tests of MH13 revealed a significantly higher flow stress in the 820–900 °C temperature interval in MH13 compared to H13. Thermo-Calc simulations showed that when reducing the Si-content from 1.0 to 0.06 wt.% the initial temperature for ferrite-to-austenite transformation (A1) was reduced from 900 °C to 820 °C. Knowing that austenite has totally different mechanical and thermal properties than ferrite, the difference in A1 between the two steels explains the higher cutting forces and higher tendency for BUE-formation. The conclusion is that the difference in machinability between H13 and MH13 is primarily related to their difference in A1.An attempt was also made to find a new tool material composition that can combine the wear resistance of MH13 and the good machinability of H13. Thermo-Calc simulations were performed with slightly modified alloying content without changing its properties as a good forming tool material, with the aim to increase A1. For instance, reducing the Mn content from 0.5 to 0.05 wt.% proved to increase A1 from 820 to 850 °C.     

Comparing intensive,extensified and organic grassland farming in southern Germany by process life cycle assessment

To reduce the environmental burden of agriculture, suitable methods to comprehend and assess the impact on natural resources are needed. One of the methods considered is the life cycle assessment (LCA) method, which was used to assess the environmental impacts of 18 grassland farms in three different farming intensities — intensive, extensified, and organic — in the Allgäu region in southern Germany. Extensified and organic compared with intensive farms could reduce negative effects in the abiotic impact categories of energy use, global warming potential (GWP) and ground water mainly by renouncing mineral nitrogen fertilizer. Energy consumption of intensive farms was 19.1 GJ ha⁻¹ and 2.7 GJ t⁻¹ milk, of extensified and organic farms 8.7 and 5.9 GJ ha⁻¹ along with 1.3 and 1.2 GJ t⁻¹ milk, respectively. Global warming potential was 9.4, 7.0 and 6.3 CO₂-equivalents ha⁻¹ and 1.3, 1.0 and 1.3 CO₂-equivalents t⁻¹ milk for the intensive, extensified and organic farms, respectively. Acidification calculated in SO₂-equivalents was high, but the extensified (119 kg SO₂ ha⁻¹) and the organic farms (107 kg SO₂ ha⁻¹) emit a lower amount compared with the intensive farms (136 kg SO₂ ha⁻¹). Eutrophication potential computed in PO₄-equivalents was higher for intensive (54.2 kg PO₄ ha⁻¹) compared with extensified (31.2 kg PO₄ ha⁻¹) and organic farms (13.5 kg PO₄ ha⁻¹). Farmgate balances for N (80.1, 31.4 and 31.1 kg ha⁻¹) and P (5.3, 4.5 and −2.3 kg ha⁻¹) for intensive, extensified and organic farms, respectively, indicate the different impacts on ground and surface water quality. Analysing the impact categories biodiversity, landscape image and animal husbandry, organic farms had clear advantages in the indicators number of grassland species, grazing cattle, layout of farmstead and herd management, but indices in these categories showed a wide range and are partly independent of the farming system.     

Reducing phosphorus in dairy diets improves farm nutrient balances and decreases the risk of nonpoint pollution of surface and ground waters

Reducing phosphorus (P) in dairy diets may result in different types of manure with different chemical composition. Application of these manures to soils may affect the soil P solubility and lead to different environmental consequences. A laboratory incubation study determined the impact of 40 dairy manures on P dynamics in two soil types, Mattapex silt loam (Aquic Hapludult) and Kalmia sandy loam (Typic Hapludult). The manures were fecal samples of lactating cows, collected from commercial dairy farms located in Northeastern and Mid-Atlantic United States, with a wide range of dietary P concentrations (from 2.9 to 5.8 g P kg⁻¹ feed dry matter, DM). Dried and ground fecal samples were mixed with surface horizon (0–15 cm) of soils at 150 kg P ha⁻¹ and the mixtures were incubated at 25 °C for 21 days. At the end of incubation, water soluble P (WS-P) and Mehlich-3 P (M3-P) in the soil–manure mixtures were substantially higher than the control (soil alone) but were lower than the soils receiving fertilizer KH₂PO₄ at 150 kg P ha⁻¹. Similarly, the relative extractability of P in soils amended with low- and high-P manures was always lower (<93%) than KH₂PO₄ suggesting that fertilizer P is more effective at increasing soil solution P in the short-term. Concentrations of WS-P or M3-P in soil–manure mixtures did not differ regardless of the source of manure (i.e. different farms and different diets). This suggests that when the same amount of P is added to soils through manure applications, the solubility or bioavailability of P in soils will be the same. However, P concentrations in feces correlate significantly with that in diets (r = 0.82^**); and when the manures were grouped into high-P diets (averaging 5.1 g P kg⁻¹) versus low-P diets (3.6 g P kg⁻¹), manure P was 40% greater in the high-P group (10.6 g kg⁻¹ DM) than the low-P group (7.6 g kg⁻¹ DM). Thus, lowering excess P in diets would reduce P excretion in manures, P accumulation in soils, improve P balance on farms, require less area for land disposal, and decrease potential for P loss to waters.     

Life-cycle environmental and economic impacts of energy-crop fuel-chains: an integrated assessment of potential GHG avoidance in Ireland

This paper combines life-cycle analyses and economic analyses for Miscanthus and willow heat and electricity fuel-chains in Ireland. Displaced agricultural land-uses and conventional fuels were considered in fuel-chain permutations. Avoided greenhouse gas (GHG) emissions ranged from 7.7 to 35.2 t CO₂ eq. ha⁻¹ a⁻¹. Most fuel-chain permutations exhibited positive discounted financial returns, despite losses for particular entities at a farm-gate processed-biomass price of €100 t⁻¹ dry-matter. Attributing a value of €10 t⁻¹ CO₂ eq. to avoided GHG emissions, but subtracting financial returns associated with displaced fuel supplies, resulted in discounted annual national economic benefits (DANEBs) ranging from −457 to 1887€ ha⁻¹ a⁻¹. Extrapolating a plausible combination of fuel-chains up to a national indicative scenario resulted in GHG emission avoidance of 3.56 Mt CO₂ eq. a⁻¹ (5.2% of national emissions), a DANEB of 167 M€, and required 4.6% of national agricultural land area. As cost-effective national GHG avoidance options, Miscanthus and willow fuel-chains are robust to variation in yields and CO₂ price, and appear to represent an efficient land-use option (e.g. compared with liquid biofuel production). Policies promoting utilisation of these energy-crops could avoid unnecessary, and environmentally questionable, future purchase of carbon credits, as currently required for national Kyoto compliance.