Progress 03/15/05 to 03/14/10
Outputs
Progress Report Objectives (from AD-416) This cooperative research proposal will investigate three key issues that are fundamental to the use of foundry sands (FSs) in agricultural and urban soil applications. The first issue relates to the physical and mineralogical properties of the FS particle size separates. The second and third issues relate to erosion characteristics of land-applied FS and FS blended products and their ability to support plant growth, respectively. Specific project objectives will be to: 1. Determine the mineralogy of spent FS particle size fractions and the swelling potential of these separates at differing temperatures. 2. Determine the erosion characteristics of land applied FS and FS blended products. 3. Evaluate the suitability of land applied FS and FS blended products for plant growth. Approach (from AD-416) Laboratory, greenhouse, and field experiments will be used to achieve the above objectives. The project will utilize spent FSs obtained from ferrous and aluminum foundries in Indiana. During year one of the project, we will determine the mineralogy of spent FS particle size fractions (by standard x-ray diffraction (XRD) methods and optical analysis using petrographic microscopy) and the swelling potential of these separates at differing temperatures. Unspent FS clays will be incrementally heated in a muffle furnace to temperatures similar to foundry processing procedures. X-ray diffraction patterns of spent FS will be compared to the x-ray diffraction patterns of the incrementally heated particle size separates in order to determine the predominant minerals present in the bulk FS. Hydraulic conductivity will be measured on the particle size separates in the laboratory using the falling head soil core method. Based on the information provided in the study above, FSs will be selected for use in subsequent erosion and plant growth studies as described below: Erosion Study: a programmable variable'intensity oscillating nozzle rainfall simulator will be used to determine the runoff characteristics of land application of FSs and FS blends under varying slope and vegetative conditions that simulate various states of urban development. Differing treatments will be applied as a topdressing to soil as well as incorporated into the soil. This research will be conducted at the USDA- National Soil Erosion Research Laboratory located on the Purdue University campus. Plant Growth Study: FS and blended products will be evaluated for their impact to plant growth. Physical and chemical properties (hydraulic conductivity, particle size distribution, cation exchange capacity, pH, electrical conductivity, and plant nutrients) will be determined on FS and FS blended with soil from the argillic horizon of common northern Indiana subsoils to simulate the incorporation of FS in urban lawns immediately following house development. Plant growth in the FS and blended FS:Soil will be analyzed in the greenhouse. Field plots will be established at the Throckmorton Purdue Agricultural Center with these mixes at the Throckmorton - Purdue Agricultural Center, located 15 miles south of the Purdue University West Lafayette campus. The USDA-sponsored beneficial reuse of waste foundry sand (WFS) project at Purdue University was completed following (1) scientific analysis of 15 different WFSs from aluminum and gray iron foundries for properties that would exhibit negative effects on plant growth if used as part of a soil amendment, (2) determination of the cause of negative effects and the development of amelioration techniques to improve WFSs, and (3) testing proposed amelioration techniques on a selected WFS under plant growth conditions. The analyses of 15 different WFSs focused on physical properties (i.e. high strength) that would be adverse to its reuse as part of a soil amendment. It was determined that WFSs from gray iron foundries produced strength values upon drying that were outside of the threshold (1.5 MPa) necessary for proper root growth and development to occur. Sodium bentonite, a type of clay used as a binding agent in the cast metal process, was identified as the cause for the high strength. Replacement of the sodium cation by calcium cations produced a beneficial response by reducing strength values below the threshold level. It was proposed that the use of gypsum or compost could provide a sufficient source of cations to replace sodium cations, reduce strength, and allow proper plant growth to occur. Under greenhouse trials with perennial ryegrass and tall fescue, two rates of gypsum addition and 7 rates of compost addition were tested on one high strength WFS for their effects on shoot growth. Though strength did not seem to have any effect on the growth of either turfgrass for any of the treatments, a WFS/compost blend was selected (40% WFS, volume basis) that would reuse the greatest amount of WFS without major reductions in turfgrass growth. The project resulted in the publication of two scientific journal articles (de Koff et al., 2008; 2010) as well as extension of information to stakeholders (Indiana Cast Metals Association, Foundry Industry Recycling Starts Today) through either written or oral presentation of the research findings. In addition, two Purdue University Extension bulletins were developed for the general population about composting. Progress for this project was measured by email and phone conversations.
Impacts
(N/A)
Publications
|
Progress 10/01/08 to 09/30/09
Outputs
Progress Report Objectives (from AD-416) This cooperative research proposal will investigate three key issues that are fundamental to the use of foundry sands (FSs) in agricultural and urban soil applications. The first issue relates to the physical and mineralogical properties of the FS particle size separates. The second and third issues relate to erosion characteristics of land-applied FS and FS blended products and their ability to support plant growth, respectively. Specific project objectives will be to: 1. Determine the mineralogy of spent FS particle size fractions and the swelling potential of these separates at differing temperatures. 2. Determine the erosion characteristics of land applied FS and FS blended products. 3. Evaluate the suitability of land applied FS and FS blended products for plant growth. Approach (from AD-416) Laboratory, greenhouse, and field experiments will be used to achieve the above objectives. The project will utilize spent FSs obtained from ferrous and aluminum foundries in Indiana. During year one of the project, we will determine the mineralogy of spent FS particle size fractions (by standard x-ray diffraction (XRD) methods and optical analysis using petrographic microscopy) and the swelling potential of these separates at differing temperatures. Unspent FS clays will be incrementally heated in a muffle furnace to temperatures similar to foundry processing procedures. X-ray diffraction patterns of spent FS will be compared to the x-ray diffraction patterns of the incrementally heated particle size separates in order to determine the predominant minerals present in the bulk FS. Hydraulic conductivity will be measured on the particle size separates in the laboratory using the falling head soil core method. Based on the information provided in the study above, FSs will be selected for use in subsequent erosion and plant growth studies as described below: Erosion Study: a programmable variable'intensity oscillating nozzle rainfall simulator will be used to determine the runoff characteristics of land application of FSs and FS blends under varying slope and vegetative conditions that simulate various states of urban development. Differing treatments will be applied as a topdressing to soil as well as incorporated into the soil. This research will be conducted at the USDA- National Soil Erosion Research Laboratory located on the Purdue University campus. Plant Growth Study: FS and blended products will be evaluated for their impact to plant growth. Physical and chemical properties (hydraulic conductivity, particle size distribution, cation exchange capacity, pH, electrical conductivity, and plant nutrients) will be determined on FS and FS blended with soil from the argillic horizon of common northern Indiana subsoils to simulate the incorporation of FS in urban lawns immediately following house development. Plant growth in the FS and blended FS:Soil will be analyzed in the greenhouse. Field plots will be established at the Throckmorton Purdue Agricultural Center with these mixes at the Throckmorton - Purdue Agricultural Center, located 15 miles south of the Purdue University West Lafayette campus. Significant Activities that Support Special Target Populations The use of indices to determine the maturity of compost is important. Immature compost can adversely affect plant growth if used as a soil amendment due to the presence of undecomposed, phytotoxic compounds and high microbial activity which can scavenge available nutrients. Different indices of compost maturity, including plant growth and seed germination bioassays, non-humic and humic acid contents, optical density, and aromaticity, were assessed for their accuracy when using compost with high salt and high pH characteristics. Plant bioassays, which are the traditional method for accessing compost maturity, afforded highly variable results over the course of this study indicating that equilibrium had not been achieved. This was most likely due to the high salinity and pH than the overall compost maturity. Optical density and aromaticity are two chemical indices that utilize sophisticated spectroscopic techniques, such as solid phase NMR (nuclear magnetic resonance), were highly suited for this situation. The change in compost with time was easily observed and provided consistent results. The two chemical indices were also strongly correlated with one another. These results indicate that optical density and aromaticity may be the best measures to use when assessing the maturity of a high-salt, high-pH compost, although the salt content and pH may need to be adjusted prior to using the compost as a soil amendment. Two manuscripts have been accepted and another is in preparation. Progress for this project was measured by email and phone conversations.
Impacts
(N/A)
Publications
|
Progress 10/01/06 to 09/30/07
Outputs
Progress Report Objectives (from AD-416) This cooperative research proposal will investigate three key issues that are fundamental to the use of foundry sands (FSs) in agricultural and urban soil applications. The first issue relates to the physical and mineralogical properties of the FS particle size separates. The second and third issues relate to erosion characteristics of land-applied FS and FS blended products and their ability to support plant growth, respectively. Specific project objectives will be to: 1. Determine the mineralogy of spent FS particle size fractions and the swelling potential of these separates at differing temperatures. 2. Determine the erosion characteristics of land applied FS and FS blended products. 3. Evaluate the suitability of land applied FS and FS blended products for plant growth. Approach (from AD-416) Laboratory, greenhouse, and field experiments will be used to achieve the above objectives. The project will utilize spent FSs obtained from ferrous and aluminum foundries in Indiana. During year one of the project, we will determine the mineralogy of spent FS particle size fractions (by standard x-ray diffraction (XRD) methods and optical analysis using petrographic microscopy) and the swelling potential of these separates at differing temperatures. Unspent FS clays will be incrementally heated in a muffle furnace to temperatures similar to foundry processing procedures. X-ray diffraction patterns of spent FS will be compared to the x-ray diffraction patterns of the incrementally heated particle size separates in order to determine the predominant minerals present in the bulk FS. Hydraulic conductivity will be measured on the particle size separates in the laboratory using the falling head soil core method. Based on the information provided in the study above, FSs will be selected for use in subsequent erosion and plant growth studies as described below: Erosion Study: a programmable variable'intensity oscillating nozzle rainfall simulator will be used to determine the runoff characteristics of land application of FSs and FS blends under varying slope and vegetative conditions that simulate various states of urban development. Differing treatments will be applied as a topdressing to soil as well as incorporated into the soil. This research will be conducted at the USDA- National Soil Erosion Research Laboratory located on the Purdue University campus. Plant Growth Study: FS and blended products will be evaluated for their impact to plant growth. Physical and chemical properties (hydraulic conductivity, particle size distribution, cation exchange capacity, pH, electrical conductivity, and plant nutrients) will be determined on FS and FS blended with soil from the argillic horizon of common northern Indiana subsoils to simulate the incorporation of FS in urban lawns immediately following house development. Plant growth in the FS and blended FS:Soil will be analyzed in the greenhouse. Field plots will be established at the Throckmorton Purdue Agricultural Center with these mixes at the Throckmorton - Purdue Agricultural Center, located 15 miles south of the Purdue University West Lafayette campus. Significant Activities that Support Special Target Populations This report documents research that is being conducted under a Specific Cooperative Agreement between ARS and Purdue University. Additional results of the research can be found in the report for the parent project 1265-12000-035-00D, �Benefits and Risks of Using Waste Foundry Sand for Agricultural and Horticultural Applications�. Waste foundry green sands were analyzed for rupture resistance (strength) after one simulated wetting and drying cycle. We determined that high strength was related to the amount of exchangeable sodium content and dispersive nature of the clays. The proposed mechanism is that these sodium-bentonites disperse when moistened and enter the interparticle areas between the clays which create clay bridges between individual sand grains when dried, adversely enhancing the strength. Clay bridging was observed in scanning electron microscope images of dried clods of high sodium-bentonite foundry sands. Clay bridging was not a prominent feature in scanning electron microscope images of the high calcium- bentonite foundry sand clods. We found that additions of gypsum decreased the strength of the sodium-bentonite waste foundry sands to levels that correspond with good root growth. We have also begun to investigate the impact of organic amendments on the high strength properties sodium-bentonite waste foundry sands. The selected sands have been composted at 0, 10, 15, and 20%, on a volume basis, with a leaf/sheep manure mixture for 4 months. Strength tests will be performed on each composted mixture. Plant growth rates for ryegrass and tall fescue will be determined for each mixture, 100% waste foundry sand, a native soil, and gypsum-amended waste foundry sand. In addition, the above strength tests and plant growth bioassays will be performed on mixtures of the pure compost blended with waste foundry sand at varying ratios. ADODR monitoring of the project is accomplished through conference calls and regular e-mails.
Impacts
(N/A)
Publications
|
Progress 10/01/05 to 09/30/06
Outputs
Progress Report 4d Progress report. This report serves to document research that is being conducted under a Specific Cooperative Agreement between ARS and Purdue University and is associated with the parent project 1265-12000-035-00D, Benefits and Risks of Using Waste Foundry Sand for Agricultural and Horticultural Applications. Waste foundry green sands from six Indiana foundries, along with 13 additional foundries from outside Indiana, were analyzed for strength to rupture of oven-dried lab-formed clods, exchangeable Na and Ca, and % clay. Some waste foundry sands exhibited high strength to rupture values (~20 kg) which may inhibit root growth and the sand's use as a soil amendment. A positive relationship was found between strength values and the % Na clay (Na bentonite) of the waste foundry sands where increasing strength may be caused by an increasing Na bentonite content. SEM images corroborate this evidence where waste foundry sand containing a greater
quantity of Na bentonite exhibited clay-bridging between particles and waste foundry sand with a lower quantity of Na bentonite and higher proportion of Ca bentonite showed clay flocculated onto each sand particle rather than binding particles together. When waste foundry sands containing more Na bentonite were saturated with 1 M Ca ions, strength values were found to decrease by ~70%. Waste foundry sands containing more Ca bentonite were saturated with 1M Na ions and observed to increase in strength value by a factor of 3. From this research, it is proposed that the adverse physical properties of waste foundry sands may be caused by high Na and ameliorated by the addition of Ca, allowing it to be reused as a soil amendment.
Impacts
(N/A)
Publications
|
Progress 10/01/04 to 09/30/05
Outputs
4d Progress report. This report describes research that is being conducted under a Specific Cooperative Agreement with Purdue University and is associated with the in-house project 1265-12000-035-00D, entitled Benefits and Risks of Using Waste Foundry Sand for Agricultural and Horticultural Applications. This is a new SCA added in February 2005 to investigate three key issues that are fundamental to the use of foundry sands in agricultural and urban soil applications. The first issue relates to the physical and mineralogical properties of the foundry sand particle size separates. The second and third issues relate to erosion characteristics of land- applied foundry sand and blended products and their ability to support plant growth, respectively. Progress to Date: Indiana foundries using green sand were reviewed for types of metals cast; of those, waste sand from three gray iron and three aluminum foundries were selected for detailed physical, chemical, and
mineralogical analyses. The particle size analysis of the samples was dominated by medium and fine sand (total sand: 94-100%; medium sand 29-65%; fine sand 29-56%), with low silt (0-2%) and clay (0-4%) content. The cation exchange capacities of these materials were low and ranged from 0.600-5.00 cmolc kg-1. Neither of these results showed major variation between gray iron and aluminum foundries. In addition to these results, X-ray diffraction patterns of differing size fractions and swelling indices are currently being determined.
Impacts
(N/A)
Publications
|
|