Ecoefficiency assessment of poultry manure management in Canada: Unlocking the economic feasibility and cost drivers of anaerobic digestion across farm scales

This study presents the first comprehensive life cycle costing (LCC) and eco-efficiency analysis of poultry manure (PM) management strategies across Canadian farm scales. Three scenarios were evaluated: direct selling of raw manure, composting, and anaerobic digestion (AD) with post-hydrolysis ammonia stripping (PHAS). Capital and operational costs were estimated based on quotes from real-world suppliers and operational data from CHFour Biogas, while performance metrics such as Net Present Value (NPV), Internal Rate of Return (IRR), Payback Period (PP), and Benefit-to-Cost ratio (B:C) were used to assess feasibility across farm sizes from 100 to 3 million birds. The results showed that while direct selling and composting are economically viable for small and medium farms, AD-PHAS becomes superior at larger scales (≥50,000–75,000 birds), driven by revenues from renewable natural gas (RNG), carbon credits (CC), and ammonium sulfate. Sensitivity analyses demonstrated that government incentives significantly affect financial feasibility as AD-PHAS requires support for implementation at lower scales but remains profitable without incentives at the largest scales. Acclimation-based alternatives to PHAS reduce OPEX but at the cost of reduced methane yield. An eco-efficiency analysis, combining normalized economic and environmental performance indicators, identified a transition zone between 20,000 and 30,000 birds where AD-PHAS becomes preferable. However, this farm scale would require joined efforts in a hub & spoke model to be economically viable. This paper provides evidence-based insights to guide policymakers, investors, and producers toward sustainable and economically feasible manure management pathways in Canada's poultry sector. • First life cycle costing of poultry manure management across Canadian farm scales • AD-PHAS identified as most eco-efficient pathway at medium-to-large poultry farms • Revenues from RNG, carbon credits, and ammonium sulfate drive AD-PHAS feasibility. • AD becomes eco-efficient at 20,000–30,000 birds, requiring hub-and-spoke models. • Reliance of AD-PHAS on governmental support decreases as farm scale increases.