Progress 01/01/11 to 12/31/15
Outputs
Target Audience:Target audiences for this project are predominantly the related industry sectors. Partnering companies do not wish to be named, but include metalcasting foundries, and companies involved in producing or supplying the biomass-based raw materials such as ligninproducers from pulp and paper industries and potentially in the future those from biorefineries, rice producers who are sourcres of silica-rich rice hull ash, and the meatpacking industry, which produces collagen and hydrolyzed collagen.In addition to the related industries, a key target audience is students, visiting scholars, and postdocs, whom we can educate through formal courses and supervised research experiences. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?This project provided training and professional development for a series of graduate students, visiting scholars, and post doctoral scholars, who focused on conducing research. Those involved also had opportunities to present their research findings at conferences and via peer-reviewed publications. How have the results been disseminated to communities of interest?Results have been disseminated by personal communication with partnering industries (companies do not wish to be named). In a broader sense, results have been communicated to the scientific community via a series of presentations (12)and also via peer-reviewed journal publications (4 published, 1 in review, 1 in draft). Undergraduate and graduate students have learned about the bricks in classes; the project demonstrates an innovative way to use waste materials to meet a societal need while offering a more environmentally suitable energy source. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
We are verypleased to report that we have successfully completed all of the milestone tasks identified above. The main products from this work include peer reviewed publications (4 published, 1 in review, 1 in draft); presentations at scientific conferences (12); students trained (4 post docs, 4 graduate students, 1 visiting scholar); and partnerships developed with related industries (coal, metal casting foundries, meatpacking industry, rice producing industries, lignin producing industries).Our publications detail our key findings relating to each area in further detail (more information is provided in the "other products" section of this report), but in sum, the following are the main accomplishments of the project: We optimized brick formulation to create strong bricks that hold up in the foundry cupola. We studied brick strength and energy values following various pyrolysis exposures, and tailored our preparation of the bricks to ensure they could handle the very demanding foundry cupola (high temperature, significant "drops" from conveyors, etc). We evaluated the thermal evolution of the chemistry and morphology of the system during pyrolysis to understand what eachcomponent of hte brick provided to the system in terms of energy and strength.And most notably, we demonstrated thesebricks work for this application: we produced 8 Tons of bricks and demonstrated them, successfully, at two partnering foundries. One publication details the results of the foundry demonstration (Nieto Delgado et al., Fuel, 2014), but it was considered a great success--we were able to replace up to 25% of the coke feed, while still meeting all required operating criteria (adequate fuel characteristics, low emissions). The metal cast parts that were made during the trial met the required specifications, and were sold. With input from industry partners, we conducted technoeconomic analyses. Aconsortium of companies including representatives from related industries (foundries, coal suppliers, lignin, gelatin, silicon suppliers; specific companies do not wish to be named)are innegotiations related to building a pilot plant to scale-up the production andutilization of these materials. In sum, the project has developed a viablesolid fuel brick that can replacecoke, a highly polluting and expensive fuel source. The fuel brick produced uses several low-value agricultural residuals, as well ascoal fines that had no prior application.Developing value-added uses for lignin (one of our key ingredients) helps to improve the economics for lignocellulosic biorefineries. The next step toward commercialization isconstructing a pilot plant that can produce tons of the bricks per day. Our partners are in discussion as to where that would be located, and who would provide the funding. Thebottleneck at this point in time is largely economic; the partners have to agree on pricing structure. They also have to negotiate thefinancial commitments to the capital investment needed to build thepilot plant.
Publications
- Type:
Journal Articles
Status:
Published
Year Published:
2016
Citation:
YD Noh, S Komarneni, FS Cannon, NR Brown, and H Katsuki. 2016. Anthracite briquettes with plant byproducts as an ecofriendly fuel for foundries. Fuel 175: 210-216.
- Type:
Journal Articles
Status:
Under Review
Year Published:
2016
Citation:
L Pena, G Mitchell, FS Cannon, S Komarneni, and NR Brown. 2016. Morphological studies on lignin-bound anthracite briquettes. Submitted to Carbon.
- Type:
Conference Papers and Presentations
Status:
Accepted
Year Published:
2015
Citation:
N. Robitaille Brown. Fuel bricks from lignin and coal fines. Society for Wood Science and Technology International Convention. June 8, 2015. Jackson, Wyoming.
- Type:
Conference Papers and Presentations
Status:
Accepted
Year Published:
2015
Citation:
L Pena Duque and NR Brown. Morphological studies on lignin-anthracite briquettes. ENFL Division, American Chemical Society. Paper 110. Sunday, March 22, 2015. Denver, Colorado.
- Type:
Conference Papers and Presentations
Status:
Accepted
Year Published:
2015
Citation:
L Pena Duque and NR Brown. Lignin-coated magnetic nanoparticles for mercury adsorption. ENVR Division, American Chemical Society. Paper 198. Tuesday, March 24, 2015. Denver, Colorado.
|
Progress 01/01/14 to 12/31/14
Outputs
Target Audience:Target audiences for this project are predominantly the related industry sectors, including metal casting foundries, and companies involved in producing or supplying the biomass-based raw materials (lignin, silica-rich ash, anthracite fines). During 2014, the team has interfaced with the following companies regarding this USDA AFRI scope: a pulp mill company, an anthracite coal processor, six foundries, a specialty graphite company, a lignin extracting company, and an entrepreneurial company that addresses coal and foundry issues. Students were another key target audience, as our work is affiliated with the University, and we train students in how to conduct research. Secondary target audiences included regulatory agencies who interface with our industrial sectors, as well as interested client groups. Reaching these groups was accomplished through extension and outreach efforts. Other target audiences during the year included attendees at the Sustainable Bioenergy Project Directors Meeting hosted by NIFA (poster presentation). Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?This project has provided opportunities to train 2 post docs, wage payroll employees, and graduate students. In 2014, the funding was allocated solely to post-docs and wage payroll employees. All participating graduate students have finished their studies and graduated. How have the results been disseminated to communities of interest?Results have been disseminated through reaching out to the relevant industries. During 2014, the team has interfaced with the following companies regarding this USDA AFRI work: a pulp mill company, an anthracite coal processor, six foundries, a specialty graphite company, a lignin extracting company, and an entrepreneurial company that addresses coal and foundry issues. We have one peer-reviewed publication submitted (Fuel) and also presented this work at the USDA Project Directors meeting (poster). The work done in 2014 by post-docs will be presented at conferences and publishedin 2015. What do you plan to do during the next reporting period to accomplish the goals?During 2015 we plan to finish our experimental efforts, largely relating to brick morphology,and write up the results, to be submitted to peer-reviewed journals.
Impacts
What was accomplished under these goals?
The accomplishments were reported in the "products" section in terms of data collected for each objective. Importantly, we have successfully demonstrated the fuel bricks industrially, preparing eight tons of bricks and using them at two foundries. Our publication cited in this report further details this demonstration effort, which was a tremendous success. The participating foundries were able to replace up to 25% of their coke load with our bricks. The metalcastparts produced during the demonstration met all required specifications, so they were sold. Also, the air quality emissions were acceptable. We are continuing to make progress towards all of the objectives, and expect additional publications in 2015.
Publications
- Type:
Journal Articles
Status:
Published
Year Published:
2014
Citation:
Nieto-Delgado, C., F.S. Cannon, P.D. Paulsen, J.C. Furness, R.C. Voigt, J.R. Pagnotti (2014). Bindered anthracite briquettes as fuel alternative to metallurgical coke: Full scale performance in cupola furnaces. Fuel, 121:39-47.
|
Progress 01/01/13 to 12/31/13
Outputs
Target Audience: Target audiences for this project are predominantly the related industry sectors, including metalcasting foundries, and companies involved in producing or supplying the biomass-based raw materials (lignin, silica-rich ash, anthracite fines). Being involved in the University, a key target audience is always students, whom we can educate in the classroom through formal courses. Pending the development of successful materials, we will deliver our knowledge to the secondary target audience including regulatory agencies who interface with our industrial sectors, as well as interested client groups. Reaching these groups will likely be accomplished through extension and outreach efforts. Other target audiences during this year included attendees at the following conferences: Carbon, American Chemical Society, the Materials Society, and the American Association for the Advancement of Industrialized Crops. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided? The four lead PIs have worked together to mentor and train junior scientists (post docs, graduate students, and undergraduate students). These students have developed not only scientific skills (how to prepare samples, conduct various experiments, evaluate and disseminate data) but also ethics and integrity in research training. How have the results been disseminated to communities of interest? Reports have been disseminated largely through presentations at scientific conferences. In 2013, these conferences included: Our work was presented at several conferences, including the Materials Research Society (San Francisco, CA), at the American Chemical Society (New Orleans, LA), and at the International Carbon Conference (Rio de Janeiro, Brazil) and at the AAIC-AFRI (The Association for the Advancement of Industrial Crops conference, Washington DC). It was also presented at several on campus seminars and expositions (Penn State University). We also have regular dialog and discussion to our industry partners, including contacts in the lignin, pulp & paper, coal, and foundry industries. What do you plan to do during the next reporting period to accomplish the goals? During the next reporting period we plan to evaluate different sources of lignin, to determine whether highly purified (and hence expensive) lignin is necessary. We also plan to modify the lignin in several ways to determine if we can obtain better adhesion. A different series of catalysts will be evaluated to determine if we can form additional quantities of silicon carbide nanowhiskers from bio-based silica rich feedstocks (instead of silicon metal).
Impacts
What was accomplished under these goals?
As explained in the outputs, this year's efforts have correlated with work under objectives 1-3. We have inevstigated the thermal fuding of biomass byproducts at temperatures from ambient to 1600C; we have studied the conversion of products into silicon carbide nanowires which impart strength; and we have investigated the fuel potential, chemistry, and strengths of the fuel bricks. The bricks have already been demonstrated at partnering foundries, using 8 Tons of bricks. The demonstrations were highly successful. We are trying to optimize the bricks to support further development.
Publications
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2013
Citation:
Frantz, C.W., N.R. Brown, F.S. Cannon, B.G. Diehl. 2013. Characterization of lignin throughout pyrolysis. American Chemical Society Spring Meeting Abstracts. April 11, 2013. New Orleans, LA. Cellulose Division. Abstract 236. http://abstracts.acs.org
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2013
Citation:
Nieto Delgado, C., F.S. Cannon, P.D. Paulsen, J.C. Furness. Bindered anthracite bricks as fuel alternative of metallurgical coke: full scale performance in a cupola furnace. July 14-19, 2013. Rio de Janeiro, Brazil. Abstract 380. http://www.carbon2013.org/site/wp-content/uploads/Carbon2013_accepted_abstracts.htmlParticipants
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2013
Citation:
Komarneni, S., H. Huang, Y.-D. Noh, N.R. Brown, F.S. Cannon. A novel cheaper and greener fuel to replace foundry coke in cupolas. 2013 Spring Materials Research Society Meeting. April 2-5, 2013. Abstract Z7.05. https://www.mrs.org/s13-program-z/
- Type:
Journal Articles
Status:
Published
Year Published:
2013
Citation:
Diehl, B.G., N.R. Brown, C.W. Frantz, M.R. Lumadue, F.S. Cannon. 2013. Effects of pyrolysis temperature on the chemical composition of refined softwood and hardwood lignins. Carbon 60: 531-537.
|
Progress 01/01/12 to 12/31/12
Outputs
OUTPUTS: Recall the main aim of our project was to develop a new foundry fuel source comprised of industrial and agricultural byproducts. This year we tested the developed technology at full scale in two foundries, and both demonstrations were successful. In each trial, we replaced up to 25% of the conventional coke with bricks that were comprised of anthracite fines, lignin, collagen, silicon, and additives. Images taken through the tuyere windows of the cupola furnace (where oxygen-enriched air was lanced into the bottom of the cupola) demonstrated that the anthracite bricks could reach the melting zone without falling apart. Also, once these bricks reached the level of the tuyere windows, they burned faster than did conventional coke. During these trials, cupola operations were stable, good iron castings were made and sold, and overall, the furnace was more energy efficient. In Year 2 we also made important gains in knowledge regarding fundamental aspects of briquette chemistry and morphology (another main objective of our work). The thermal (pyrolytic) evolution of lignin chemistry was studied via X-ray diffraction (XRD), Raman, Fourier Transform Infrared Spectroscopy and solid state Nuclear Magnetic Resonance (NMR) spectroscopy. The chemistry of the lignin evolved, losing oxygenated functional groups and aliphatic groups with increasingly aggressive pyrolysis exposures. The lignin samples also became more ordered (XRD and Raman) following pyrolytic exposures. Acid-base potentiometric titration work also began to give insight into the reactivity of various lignin functional groups. Functionalities with a pKa above 8.5 (phenol) significantly increased the strength. Another objective in this research was to utilize bio-product silica (rice hull ash or rice hull powder) as a replacement for silicon metal, in order to form silicon carbide (SiC) nanowires which impart strength to the anthracite fuel bricks at temperatures greater than 1000 C. Our studies during last year indicated that the silicon powder could be replaced to some extent by both the bio-product silicas which led to higher mechanical strength of anthracite bricks. Based on these studies, we investigated the strength of anthracite bricks affected by the content of silicon metals or lignin along with the addition of bio-silica. We also examined the formation of silicon carbide nanowires or the strength improvement of the bricks by adding different catalysts or components without the expensive Si powder. One graduate student and two post-doctoral researchers were mentored by project PIs as a result of this funding. Additional graduate and undergraduate students have been involved in various aspects of the experimental work. Collaboration is being fostered by this funding, both among project PIs, as well as with our industry partners. To date, the work has been disseminated at scientific conferences, including the American Chemical Society, Carbon, Frontiers in Biorefining, and Materials Research Day at Penn State. PARTICIPANTS: Participants in the project include the PIs: Dr. Nicole Brown, Dr. Fred Cannon, Dr. Sridhar Komarneni, and Dr. Bob Voigt at Penn State University. At Furness-Newburge, Inc, Mr. Jim Furness is a participant. Dr. Cesar Nieto and Young Dong Noh have been involved as postdoctoral researchers funded by this grant, and the following graduate students have also received funding from USDA NIFA for work on this project: Curtis Frantz, and Lasita Bhattacharya. Additional work (not funded by NIFA) has been contributed by graduate students Brett Diehl, Matt Lumadue, and Allura Jiles. Partnering organizations for this work include the Ben Franklin Technology Partners program, Furness-Newburge, Inc., Innventia, and Riceland. In the future we expect additional partnering organizations from the lignin supply industry (Domtar, Appleton), as well as other companies producing silica-rich biomass, and interested foundries. Collaborators for the work include our colleagues at the Penn State user facilities (Dr. Alan Benesi, NMR; Dr. Joe Stitt, Raman; Dr. Josh Stapleton, FTIR; Dr. Nicole Wonderling, XRD). We have also had interactions with Dr. Harold Schobert regarding his expertise in characterizing anthracite. Participating students and post-docs are all engaged in activities providing key aspects of technical training and professional development, as consistent with their typical University duties. TARGET AUDIENCES: Target audiences for this project are predominantly the related industry sectors, including metalcasting foundries, and companies involved in producing or supplying the biomass-based raw materials (lignin, silica-rich ash, anthracite fines). Being involved in the University, a key target audience is always students, whom we can educate in the classroom through formal courses. Pending the development of successful materials, we will deliver our knowledge to the secondary target audiences including regulatory agencies who interface with our industrial sectors, as well as interested client groups. Reaching these groups will likely be accomplished through extension and outreach efforts. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
During Year 2 efforts, several key outcomes or impacts have resulted. We have learned techniques for successfully pyrolyzing our materials, we have developed an approach to make briquette samples in the lab and our industrial partners have developed methods of forming industrial scale bricks. In addition, we have learned and applied techniques to successfully characterize various elements of these briquettes via FTIR, Raman, and NMR spectroscopies, as well as XRD and SEM. Several publications will result from these efforts. Some of the principles we are learning may lead to reduced volatile organic compound emission, and less fossil fuel consumption at foundries.
Publications
- Frantz, C. W., N. R. Brown, F. S. Cannon, M. R. Lumadue, and B. G. Diehl. 2012. Pyrolizing lignin to create a new foundry fuel source. American Chemical Society Spring Meeting Abstracts. March 25, 2012. San Diego, CA. Cellulose Division. Publication number 55. http://abstracts.acs.org.
- Brown, N., F. Cannon, S. Komarneni, M. Kumadue, C. Frantz, B. Diehl, Y. Noh, R. Voigt, and J. Furness. 2012. A novel foundry fuel source. Materials Day and Abstract Book Annual Meeting. April 23-24, 2012. State College, PA. P38. http://www.mri.psu.edu/events/materials_day/2012/2012_MaterialsDay_Pr ogram.pdf.
- Lumadue, M. R., F. S. Cannon, and N. R. Brown. 2012. Lignin as both fuel and fusing binder in briquetted anthracite fines for foundry coke substitute. Fuel 97: 869-875. http://dx.doi.org/10.1016/j.fuel.2012.02.061.
- Lumadue, M., F. Cannon, and N. Brown. 2012. Lignin as Both Fuel and Fusing Binder in Briquetted Anthracite Fines for Foundry Coke Substitute. Carbon 2012 Conference. June 17-22, 2012. Krakow, Poland. (Abstract 383) http://www.carbon2012.pl/en/.
- Frantz, C., N. Brown, M. Lumadue, F. Cannon, and S. Komarneni. 2012. Pyrolysis of Lignin to Create a New Foundry Fuel Source. Frontiers in Biorefining 2012. October 30-November 2, 2012. St. Simons Island, GA. http://www.frontiersinbiorefining.org.
|
Progress 01/01/11 to 12/31/11
Outputs
OUTPUTS: During year 1, a series of fundamental experiments were conducted to better understand the effects of various compositional factors on the ultimate performance of our coke-replacement briquettes. The strength of the briquettes was evaluated via unconfined compressive strength tests after varying the following factors: the type and amount of lignin, the amount of other binders, silicon metal content, silica-rich rice hull ash content, pyrolysis time, pyrolysis temperature, and compaction pressure. Promising results were obtained, indicating we can produce briquettes that will maintain structural integrity within the foundry cupola ( a critical parameter for a potential coke replacement). In our proposal, a key aspect was also understanding the science and chemistry involved in the evolution of the biomass residues as they were exposed to the pyrolysis treatments. The thermal evolution of lignin chemistry in the pyrolyzing environment was studied for several types of lignin via FTIR spectroscopy and solid state NMR. Potentiometric titration work was also begun to give insights into the reactivity of various lignin functional groups. We also hypothesized that silica rich biomass could successfully replace silicon metal, all or in part. Xray diffraction studies were conducted to provide insight into the formation of silicon carbide nanowires, which provide briquette strength. Two graduate students and one post-doctoral researcher are being mentored by project PIs as a result of this funding. Additional graduate students have been involved in various aspects of the experimental work. Collaboration is being fostered by this funding among project PIs as well as relevant industry partners. To date, the work has been disseminated at scientific conferences, including the American Chemical Society Spring Convention. PARTICIPANTS: Participants in the project include the PIs: Dr. Nicole Brown, Dr. Fred Cannon, Dr. Sridhar Komarneni, and Dr. Bob Voigt at Penn State University. At Furness-Newburge, Inc, Mr. Jim Furness is a participant. Dr. Cesar Nieto has been involved as a post doctoral researcher funded by this grant, and the following graduate students have also received funding from USDA NIFA for work on this project: Curtis Frantz, Young Dong Noh, and Lasita Bhattacharya. Additional work (not funded by NIFA) has been contributed by graduate students Brett Diehl, Matt Lumadue, and Allura Jiles. Partnering organizations for this work include the Ben Franklin Technology Partners program, Furness-Newburge, Inc., Innventia, and Riceland. In the future we expect additional partnering organizations from the lignin supply industry (Domtar, Appleton),as well as other companies producing silica-rich biomass, and interested foundries. Collaborators for the work include our colleagues at the Penn State user facilities (Dr. Alan Benesi, NMR; Dr. Josh Stapleton, FTIR; Dr. Nicole Wonderling, XRD). We have also had interactions with Dr. Harold Schobert regarding his expertise in characterizing anthracite. Participating students and post-docs are all engaged in activities providing key aspects of technical training and professional development, as consistent with their typical University duties. TARGET AUDIENCES: Target audiences for this project are predominantly the related industry sectors, including metalcasting foundries, and companies involved in producing or supplying the biomass-based raw materials (lignin, silica-rich ash, anthracite fines). Being involved in the University, a key target audience is always students, whom we can educate in the classroom through formal courses. Pending the development of successful materials, we will deliver our knowledge to the secondary target audience including regulatory agencies who interface with our industrial sectors, as well as interested client groups. Reaching these groups will likely be accomplished through extension and outreach efforts. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
In the course of our Year 1 efforts, several key outcomes or impacts have resulted. We have learned techniques for successfully pyrolyzing our materials, we have developed an approach to make briquette samples and we have learned and applied techniques to successfully characterize various elements of these briquettes. We expect several publications to result from these efforts, which will be included in our Year 2 report. Some of the principles we are learning may lead to less volatile organic compound emission, and less fossil fuel consumption at foundries. However, further testing and analyses are needed to confirm these preliminary results.
Publications
- Lumadue, M. R., F. S. Cannon, N. R. Brown, and J. T. Fox. 2011. Lignin as both fuel and fusing binder in briquetted anthracite fines for foundry coke substitute. Electronic conference proceedings, 241st ACS meeting. Anaheim, CA. March 30, 2011.(Abstract 267).
- Diehl, B. G., N. R. Brown, F. Cong, and M. Tien. 2011. Investigation of Lignin-Protein Covalent Linkages. Electronic conference proceedings, 241st ACS meeting. Anaheim, CA. March 31, 2011. (Abstract 273).
|
|