Progress 07/22/05 to 06/30/10
Outputs
Progress Report Objectives (from AD-416) The specific goals of the expanded research are to: 1. Develop two-dimensional mechanistic models of grain commingling in lab- scale and full-scale bucket elevator boots. Appropriate modeling methods have been identified�the discreet element method will be used�and needed grain physical properties have been tabulated from the literature. 2. Determine the effect of repeated handling on particle size distribution of dust emissions from corn and wheat during elevator handling. Experimental protocols were developed during testing with feed pellet handling that can be applied to measurements with wheat and corn. Approach (from AD-416) Additional data will be obtained on commingling during elevator handling and the expert system will be modified to include the new data. Remedies for commingling problems will be investigated such as retrofitting or designing equipment to be self-cleaning and identifying appropriate clean- out time for equipment to achieve the desired level of self-cleaning. Retrofitting elevator legs and truck dump pits to make them self-cleaning will be studied. Parameters for the design of IP-friendly grain elevator systems will be developed. Current data on dust emission and particle size distribution during grain and feed handling will be extended to include the affects of type of grain or feed, moisture content, grain quality, drop height, and a wider range of flow rates in the receiving area of the GMPRC elevator. Isokinetic extractive sampling using high volume samplers will be used for measuring dust emissions. Particle size distribution (PSD) analysis of total suspended particulates will be erformed to determine particulates less than 10 mm (PM10) and, possibly, other sizes. The effect on grain quality will be evaluated by analysis of variance, as will the effect of grain flow rate and drop height and their interactions for each grain type. Unwanted grain commingling, which impedes new quality-based grain handling systems, has proven to be an expensive and time consuming issue to study experimentally. A more economical method to study grain commingling is through the use of "mechanistic" modeling, which uses discrete element method (DEM) software to simulate the movement of each individual grain particle in the system. Grain commingling in a pilot- scale bucket elevator boot was modeled with quasi-two-dimensional and three-dimensional models and validated in experiments with two colors of soybeans. Predicted results followed the experimental data well. The quasi-two-dimensional model significantly reduced computational time without sacrificing the three-dimensional effects of interacting spheres as would happen in a normal two-dimensional model. Both models responded correctly to small refinements to elevator boot geometry and other physical inputs, leading to very close agreement with experimental results. The quasi-two-dimensional model reduced simulation run time by 60% compared to the three-dimensional model. The resulting model is being applied to full-scale boots to determine best management practices for reducing unwanted grain commingling. These activities were monitored via numerous meetings with the cooperator to discuss project plans and review program goals and accomplishments, along with personal oversight of the research, the majority of which was performed in ARS facilities.
Impacts
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Progress 10/01/08 to 09/30/09
Outputs
Progress Report Objectives (from AD-416) The specific goals of the expanded research are to: 1. Develop two-dimensional mechanistic models of grain commingling in lab- scale and full-scale bucket elevator boots. Appropriate modeling methods have been identified�the discreet element method will be used�and needed grain physical properties have been tabulated from the literature. 2. Determine the effect of repeated handling on particle size distribution of dust emissions from corn and wheat during elevator handling. Experimental protocols were developed during testing with feed pellet handling that can be applied to measurements with wheat and corn. Approach (from AD-416) Additional data will be obtained on commingling during elevator handling and the expert system will be modified to include the new data. Remedies for commingling problems will be investigated such as retrofitting or designing equipment to be self-cleaning and identifying appropriate clean- out time for equipment to achieve the desired level of self-cleaning. Retrofitting elevator legs and truck dump pits to make them self-cleaning will be studied. Parameters for the design of IP-friendly grain elevator systems will be developed. Current data on dust emission and particle size distribution during grain and feed handling will be extended to include the affects of type of grain or feed, moisture content, grain quality, drop height, and a wider range of flow rates in the receiving area of the GMPRC elevator. Isokinetic extractive sampling using high volume samplers will be used for measuring dust emissions. Particle size distribution (PSD) analysis of total suspended particulates will be erformed to determine particulates less than 10 mm (PM10) and, possibly, other sizes. The effect on grain quality will be evaluated by analysis of variance, as will the effect of grain flow rate and drop height and their interactions for each grain type. Significant Activities that Support Special Target Populations The objective of this cooperative research is to improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. Experimental studies of grain handling operations can be expensive and time-consuming, but computer simulations can reduce the large effort required to evaluate the flow of grain. Numerous particle models were developed and evaluated for soybeans, based on known physical properties and using up to four overlapping fundamental spherical particles, for incorporation into discrete element method (DEM) simulation models of grain handling. The best single-sphere soybean particle model simulated drop height, bulk density, and angle of repose tests as well as or better than the more complex multi-sphere models with up to four overlapping spheres. The single-sphere model greatly reduced simulation time compared to other models, which greatly expands the range of useful simulations of grain handling operations that can be carried out with the DEM models. These activities were monitored via numerous meetings with the cooperator to discuss project plans and review program goals and accomplishments, along with personal oversight of the research, the majority of which was performed in ARS facilities.
Impacts
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Publications
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Progress 10/01/07 to 09/30/08
Outputs
Progress Report Objectives (from AD-416) The specific goals of the expanded research are to: 1. Develop two-dimensional mechanistic models of grain commingling in lab- scale and full-scale bucket elevator boots. Appropriate modeling methods have been identified�the discreet element method will be used�and needed grain physical properties have been tabulated from the literature. 2. Determine the effect of repeated handling on particle size distribution of dust emissions from corn and wheat during elevator handling. Experimental protocols were developed during testing with feed pellet handling that can be applied to measurements with wheat and corn. Approach (from AD-416) Additional data will be obtained on commingling during elevator handling and the expert system will be modified to include the new data. Remedies for commingling problems will be investigated such as retrofitting or designing equipment to be self-cleaning and identifying appropriate clean- out time for equipment to achieve the desired level of self-cleaning. Retrofitting elevator legs and truck dump pits to make them self-cleaning will be studied. Parameters for the design of IP-friendly grain elevator systems will be developed. Current data on dust emission and particle size distribution during grain and feed handling will be extended to include the affects of type of grain or feed, moisture content, grain quality, drop height, and a wider range of flow rates in the receiving area of the GMPRC elevator. Isokinetic extractive sampling using high volume samplers will be used for measuring dust emissions. Particle size distribution (PSD) analysis of total suspended particulates will be erformed to determine particulates less than 10 mm (PM10) and, possibly, other sizes. The effect on grain quality will be evaluated by analysis of variance, as will the effect of grain flow rate and drop height and their interactions for each grain type. Significant Activities that Support Special Target Populations The objective of this cooperative research is to improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. An estimated 80% of non-ruminant animal feed in the U.S. is pelleted -- a form that improves the efficiency of feeding and the convenience of feed handling. Feed pellets need to be durable and of high quality to withstand the handling and transportation process after production. To evaluate breakage and durability of corn-meal-type feed pellets, the pellets were repeatedly transferred between two storage bins in the USDA- ARS, Grain Marketing and Production Research Center research elevator at Manhattan, Kansas and results were compared with that of shelled corn. The apparent size of feed pellets decreased with repeated transfers, whereas the amount of broken pellets increased, but by significantly different amounts than occurred with shelled corn. Both feed pellets and shelled corn withstood eight repeated elevator handlings without a significant change in durability as measured by the standard tumbling box test, although the accumulated breakage of feed pellets was 50% after eight transfers as compared to 6.2% for shelled corn. These results will be valuable for feed and grain handlers for evaluating and improving their handling and transportation procedures. Dust generated during grain handling can pose a safety and health hazard and is an air pollutant. Fifty percent of the 245 reported grain dust explosions in the United States from 1986-2005 were in grain elevators. Due to the high organic content and small size of the particles, high concentrations of grain dust pose an explosion hazard, with smaller grain dust particles causing more powerful explosions. In addition, prolonged exposure to grain dust can harm grain-handling workers� health. To characterize the dust generated during handling of wheat and shelled corn dust samples were collected from the lower and upper ducts upstream of the cyclone dust collectors in the research elevator of the USDA Grain Marketing and Production Research Center. For both wheat and shelled corn, at an average grain flow rate of 54.4 t/h, the size distribution of dust from the upper and lower ducts showed similar trends among grain lots and repeated transfers but differed between the two ducts. The corn produced significantly more of the smaller dust particles than did wheat, and produced more than twice as much total dust -- 185 g/t of corn handled -- than did wheat. These results will be valuable for feed and grain handlers and grain elevator operators for evaluating and improving their handling and sanitation procedures to reduce their safety and health hazards and air pollution problems. These activities were monitored via numerous meetings with the cooperator to discuss project plans and review program goals and accomplishments, along with personal oversight of the research, the majority of which was performed in ARS facilities.
Impacts
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Progress 10/01/06 to 09/30/07
Outputs
Progress Report Objectives (from AD-416) Improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. Approach (from AD-416) Additional data will be obtained on commingling during elevator handling and the expert system will be modified to include the new data. Remedies for commingling problems will be investigated such as retrofitting or designing equipment to be self-cleaning and identifying appropriate clean- out time for equipment to achieve the desired level of self-cleaning. Retrofitting elevator legs and truck dump pits to make them self-cleaning will be studied. Parameters for the design of IP-friendly grain elevator systems will be developed. Current data on dust emission and particle size distribution during grain and feed handling will be extended to include the affects of type of grain or feed, moisture content, grain quality, drop height, and a wider range of flow rates in the receiving area of the GMPRC elevator. Isokinetic extractive sampling using high volume samplers will be used for measuring dust emissions. Particle size distribution (PSD) analysis of total suspended particulates will be erformed to determine particulates less than 10 mm (PM10) and, possibly, other sizes. The effect on grain quality will be evaluated by analysis of variance, as will the effect of grain flow rate and drop height and their interactions for each grain type. Significant Activities that Support Special Target Populations This report serves to document research conducted under a specific cooperative agreement between ARS and Kansas State University. Additional details of research can be found in the report for the parent CRIS 5430- 43440-005-00D, Improved Handling and Storage Systems for Grain Quality Maintenance and Measurement. The objective of this cooperative research is to improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. Grain handling and commingling in elevator equipment will be simulated using a discrete element method (DEM), which requires individual kernel properties such as Poisson�s ratio, shear modulus, and particle density and kernel surface characteristic such as the shape and surface radius. These kernel characteristics have been tabulated for soybean, corn, wheat, sunflower seed, and canola. Also, new data were obtained from repeated handling of shelled corn in the USDA-ARS, Grain Marketing and Production Research Center research elevator at Manhattan, Kansas. Data are being evaluated on corn breakage and dust emissions during handling and a manuscript is being prepared. These activities were monitored via numerous meetings with the cooperator to discuss project plans and review program goals and accomplishments, along with personal oversight of the research, the majority of which was performed in ARS facilities.
Impacts
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Progress 10/01/05 to 09/30/06
Outputs
Progress Report 4d Progress report. This report serves to document research conducted under a specific cooperative agreement between ARS and Kansas State University. Additional details of research can be found in the report for the parent CRIS 5430- 43440-005-00D, Improved Handling and Storage Systems for Grain Quality Maintenance and Measurement. The objective of this cooperative research is to improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. In tests of repeated handling of feed pellets in the USDA-ARS, Grain Marketing and Production Research Center research elevator at Manhattan, Kansas, the average mass of dust removed per transfer was 0. 069% of the mass of pellets, which was not significantly different than previous tests with shelled corn for eight transfers. Overall, 50% of dust
collected was fine dust (less than or equal to 125 microns), which was a smaller percentage than that collected with shelled corn, indicating that these pellets produced less dust emissions during handling than shelled corn.
Impacts
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Progress 10/01/04 to 09/30/05
Outputs
4d Progress report. This report serves to document research conducted under a specific cooperative agreement between ARS and Kansas State University. Additional details of research can be found in the report for the parent CRIS 5430- 43440-005-00D, Improved Handling and Storage Systems for Grain Quality Maintenance and Measurement. The objective of this cooperative research is to improve IP grain handling and reduce grain dust emissions by measuring existing grain commingling and dust emissions and developing procedures, decision support systems, and instrumentation to facilitate improved handling operations. Additional data will be obtained on commingling during elevator handling and the expert system will be modified to include the new data. Remedies for commingling problems will be investigated such as retrofitting or designing equipment to be self-cleaning and identifying appropriate clean-out time for equipment to achieve the desired level of self-cleaning.
Retrofitting elevator legs and truck dump pits to make them self-cleaning will be studied. Parameters for the design of IP- friendly grain elevator systems will be developed.
Impacts
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