Progress 09/01/08 to 08/31/09
Outputs
OUTPUTS: The University of Northern Iowa's National Ag-Based Lubricants (NABL) Center has grown into a nationally-recognized lubricants development and testing laboratory, with an impressive array of analytical, tribology, physiochemical, and performance testing equipment. In fact, the NABL Center is one of the only research facilities to be focused specifically on biobased lubricants. NABL has the capability to fully formulate, analyze, and conduct performance testing, in-house, on virtually any biobased lubricant product from soybean oil-based railroad track grease to soybean or canola oil-based metalworking fluids and machining coolants. The Center's research has resulted in numerous patents and the commercialization of over 40 soy-based grease and lubricant products, which provide for growth of rural economies, environmental benefits, and reduced national dependence on imported petroleum. Biolubricants, when compared with other biobased products, provide a uniquely wide margin on the agricultural feedstocks incorporated. While the most expensive biofuel may sell for $4 per gallon, the least expensive biolubricant often costs over $8 per gallon. In addition, the $20 billion domestic U.S. lubricants industry provides critical diversification opportunities for bioprocessing facilities. NABL's accomplishments for 2008 include successful projects which will continue to be developed in coming years. First, NABL initiated novel research investigating improvements in biolubricants manufacturing efficiency, by using microwave energy as a replacement for traditional heating methods. Initial results indicate that traditional biolubricants process heating methods not only require more energy input per unit of heat captured in the process and cost more to operate due to heat transfer inefficiencies, but that these traditional processes also initiate oxidative break-down processes in vegetable oils. Second, NABL staff conducted initial diesel engine testing to evaluate bio lubricants in the engine crankcase. The opportunity to use biobased lubricants in the diesel engine crankcase is a direct result of the improved technologies to control oxidative breakdown of vegetable oils, obtained through continuing research in chemical and genetic modifications of vegetable oils to achieve stability unheard of just 2-3 years ago. Third, NABL's staff and director participated in several important industry support activities during 2008, i.e. ASTM Crosscheck Programs (round robin testing to confirm test methodologies for biobased lubricant products); initial face to face meetings and ongoing discussions toward eventual testing and evaluation of estollides derived from vegetable oils (in conjunction with USDA's Peoria ARS) for biolubricants; it is believed that this technology developed at USDA's Peoria, IL, ARS may provide the impetus for the next major step forward in biolubricants technology. Finally, the NABL Center has actively investigated the potential application of nano- metals for control of bacteria which cause premature lubricant failure in CNC machining and other lubrication environments. PARTICIPANTS: Dr. Lou A. T. Honary is a tenured Associate Professor at the University of Northern Iowa, and the founding Director of the National Ag-Based Lubricants (NABL) Center. He has authored numerous technical publications, including a chapter on vegetable oil-based lubricants in a popular engineering handbook. Dr. Honary has cultivated strong relationships with bi-partisan political leaders at the local, state, and federal levels; his advocacy has facilitated the development of five significant pieces of legislation in the State of Iowa, which continue to encourage the use of biobased lubricants. Dr. Honary has served a leadership role in many state and local organizations. He has previously served on Governor Vilsack's Advisory Committee and as a member of Hawkeye Community College's Foundation Board, Rotary International, and in various committee membership roles with trade organizations, including Society of Tribologists and Lubrications Engineers (STLE). In 2000, Dr. Honary and the University of Northern Iowa Research Foundation jointly formed a private entity to commercialize the technologies developed by the NABL Center. The result was the creation of the first biobased lubricants company in the nation, Environmental Lubricants Manufacturing, Inc. (ELM), of Plainfield, IA. Considered one of the most knowledgeable researchers in the nation for his field, Dr. Honary is a sought-after presenter in the area of Ag-based lubricants, and one of the most recognized experts in his field. TARGET AUDIENCES: The corporate infrastructure for delivering large-volume commodity crops to market is currently undergoing extensive organizational change. Facilities, practices, and logistical and transportation mechanisms are being modified for a higher degree of "synchronization" between both the input and output sides of farm production. Specialty seeds, designed for predetermined end-use applications are beginning to emerge; facilities to isolate and process them near their origin points are showing signs of becoming smaller and more integrated among broader end-use applications. Provided there is a means to do so, opportunity to institute a cost effective manufacturing platform tailored to the specific production requirements of a growing base of specialty oils is likely within this transition. UNI-NABL comprehensively pursues broad-spectrum issues that facilitate the transition toward crop-based lubricants. To date, UNI-NABL has developed, demonstrated, and commercialized vegetable-based lubricants targeted to meet existing performance specifications; has expanded political and consumer awareness that vegetable oils are viable alternatives; has supported legislative action to position vegetable oils more attractively; and has centralized dialogue between vegetable oil producers and lubricant distributors. PROJECT MODIFICATIONS: Not relevant to this project.
Impacts
Each year 2.5 billion gallons (approximately 20 billion pounds) of lubricants are produced by U.S. refiners, of which the majority is released into the environment ("lost-in-use" products). At the same time, the United States is the world's leading producer of soybeans, generating over 12 billion pounds annually, and accounting for about half of world soybean production. Soybeans alone can replace a large portion of these lubricants, creating market opportunities for farmers and reducing our dependence on oil imports. USDA sponsorship (and that of other funding agencies) has enabled the NABL Program to develop over 40 biobased lubricants and greases currently in commercial use, and to make inroads with major industrial users, assisting in the conversion of entire operations to biolubricants (in the railroad and trucking industries respectively). Not only has ABIL demonstrated the relative value of biolubricants, but this program has imparted a direct benefit to industry and to the agricultural community at large; owing to their steadfast commitment to the research, development, demonstration and advocacy of these products. Some of the incentives derived from soybean-based lubricants can be summarized as follows: Biolubricants possess inherent performance features that add value to the lubricants industry, such as substantially higher viscosity index, better lubricity, and better adherence to metals than conventional alternatives. Bioblubricants offer environmental, health and safety value, including low toxicity and higher flash and fire points. ABIL's soy products are formulated to be "readily" biodegradable (biodegrading by a minimum of 60% within a 28-day period) and lower in toxicity to the extent possible. Value-added opportunities for farmers and agri-business are realized, providing potential for rural development and enhanced commodity prices. A GMO soybean variety cultivated exclusively for lubricant use provides a $1/bu premium to growers, with minimal yield drag. Biolubricants, derived from renewable resources, lessen our dependence on imports, and offer to lessen upstream pollution associated with petroleum extraction and refining. Cooperative field testing has verified operational benefits to industry such as increased productivity and efficiency gains, and energy savings (decreased water usage, etc.). UNI-ABIL has been successful in building a basic performance identity for these products and, for some, has made the product cost competitive. As the National Ag-Based Lubricants Center (NABL), the program will address biobased lubricant performance standards, testing protocols and environmental, health and safety advantages - all essential to the widespread adoption of biolubricants.
Publications
- In 2009 NABL founding director and professor, Dr. Lou A.T. Honary, has been active in promoting biolubricants, including several articles published in industry journals, presentations at numerous industry conferences throughout the US and Canada, including SAE and the Pacific Rim Summit on Biorenewable Products, and publishing three issues of the UNI-NABL Advocate, the Centers newsletter covering NABL activities and accomplishments. With support from USDA and other funding sources, Dr. Honary completed the following:
- Janary Through December 2009, Honary completed the following writing materials that are currently under final review for publication:
- 1. Honary, 2009. Chapter 8: Industrial Oils in Singh Bharat, Industrial Crops and Uses.
- 2. Honary, 2009. Chapter Update: Updated a chapter originally written in 2000 in the George Totten (ed.) Handbook of Hydraulic Fluid Technology.
- 3. Honary, 2009. Wrote a book on Biobased Lubricants and Greases which is currently on the final stages of proofing for publication by Wiley & Sons in UK.
- 4. Honary, 2009. Co-Editor of an ASTM Book on biofuels currently underway.
- Jun. 2009: Dr. Honary as Keynote Speaker presenting at the Annual Meeting of the National Lubricating Grease Institute.
- May 2009: Cover Story: Homegrown Engine Oil. pp. 10-13. OEM Off-Highway magazine. Volume 27, Number 5, May 2009.
- Honary, A. T. (2009 Spring). Biobased Engine Oils Possible via CORS. NABL Advocate.
- Apr. 2009: Dr. Honary Presented at the European Lubricating Grease Institutes Annual Meeting on new developments in biobased greases including Microwave Based Grease manufacturing Process.
- Feb. 16, 2009: Presentation given by Dr. Lou A.T. Honary at NLGI (National Lubricating Grease Institute) annual meeting in India.
- Jan. 2009: Dr. Honary as Keynote Speaker for the India Chapter of the National Lubricating Grease Institute, in India
- Honary, A. T. (2008 Fall). Research Expands to Automotive Lubes and Fuels. NABL Advocate.
- Honary, A. T. (2008 Summer). Biofuels Byproducts Find Use in Drilling Oil. NABL Advocate.
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