Progress 10/26/10 to 05/31/15
Outputs
Progress Report Objectives (from AD-416): Our goal is to increase the profitability of the U.S. cotton production system through new and improved cotton ginning equipment and processes resulting in enhanced market value and utility of ginned cotton lint in the global market. We will focus on the following objectives: 1) Refine the design, operation, and management of existing cotton ginning machinery to increase productivity and reduce short fiber content, neps, and seed coat fragments; 2) Improve cotton gin processing by comprehensively investigating the impact of cotton cultivar on fiber quality and non-lint content and develop improved relationships between measurable cotton traits and the value of the final products; 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use; and 4) Optimize the entire ginning system from module to bale, particularly related to air quality issues, energy use, and control of cotton moisture content. Approach (from AD-416): The objectives are interrelated and success in one contributes to success in another. Improved measurement and control will allow better response to changing gin conditions, including those caused by variation in cultivar. Better machinery design and management can be used to respond to these variations in seed cotton. Improved ginning machinery and better measurements of the cotton being processed will contribute to optimization of the entire ginning system. 1) Refine the design, operation, and management of existing cotton ginning machinery. We will test modifications to existing machinery and new machine designs for the three main functions of ginning machines�seed cotton cleaning, fiber-seed separation, and lint cleaning. We plan to develop machinery with adjustable operating parameters for use in control systems to optimize product value and quality. New management strategies will also be tested. 2) Improve cotton gin processing by improving measurement and use of measurements. Three issues will be addressed under this objective: 1) some important properties are unidentified; 2) no technique exists for measuring certain important properties, particularly in real-time at the gin; and 3) analysis using the current variables results in interactions, which may result from not measuring the correct variables or an incomplete understanding of the processes. First, we will simplify the control problem using cotton from a limited number of known cultivars and growth conditions. Second, we will find measurable traits which will allow adjustments to the ginning process for optimal processing of different cultivars, without knowledge of the cultivar. Finally, a control system using these properties will be developed to maximize fiber value and quality, accounting for variation due to cultivar and growth conditions. 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use. Currently, many important properties to gin management cannot be measured accurately, or in real- time at the gin. Sensors will be developed to measure these parameters. Advanced statistical techniques will be used to integrate information from many sensors and develop predictive models. The final step will be to develop a control system using these sensors and logic which will result in improved gin management, as demonstrated by improved fiber quality or more efficient use of resources. 4) Optimize the entire ginning system from the seed cotton module to lint, seed, and byproduct use. Dust emissions from cotton gins will be measured, so that regulatory agencies have accurate data. Energy use will be monitored throughout cotton gins. Systems will be designed that can alert ginners to conditions reducing energy efficiency or automatically conserve energy without negatively impacting gin processing. Improved systems will be designed for controlling drying and moisture addition to improve gin efficiency, product storage, and fiber quality. The operation of various cleaning machines in the gin has been studied to show that operating them at greater than rated capacity, as is being done in many commercial gins, has few drawbacks. Work is continuing into the next Plan to further examine the limits on the current equipment, to more clearly document the problems, and to potentially redesign equipment for greater capacity. Modern control equipment allows adjustment of equipment during operation at a reasonable cost, and data has been assembled which will allow implementing such control in the next plan. Different cottons are known to respond differently to gin machines. Progress has been made in understanding what some of the differences are and is expected to be able to process cotton better in the future across cultivar and weather differences. Several new useful measurements have been tested in gins but significant improvements will not be achieved before the next plan. ARS scientists at the Cotton Ginning Research Unit have proved that Roller ginning usable in the humid eastern portion of the U.S. cotton production area and produces lint with superior properties. An air-based lint cleaner has been demonstrated which cleans the fiber adequately with less fiber damage than the traditional design. Much better documentation of commercial bale moisture content (mc) measurement device has been developed based on stakeholder request. The manufacturer has improved the device after these data were published which will improve gin operation, especially reducing the excessive use of drying. However, additional mc measurements at other places in the gin are needed. Greatly improved data on dust emissions has been developed and published. These publications are changing the ambient air control for cotton gins in many locations. Significant additions to the understanding of the use of energy in gins have been made. Reductions in the energy requirements have been made in some gins and expect that considerable additional reductions will be made during the next plan. Accomplishments 01 Establishment of cotton bale moisture content measurement. U.S. gins use energy to dry cotton but have little upon which to base the moisture content (mc) level other than manual feel. The mc of cotton and non-lint materially affects the operation of every machine in the gin, drier cotton cleans more easily but is damaged more during subsequent processing. In addition, recent regulations require that bales leaving the gin be below a certain mc level to avoid spoilage during storage. A commercial device was available which indicated the mc of the bale as it leaves the gin and was being adopted by some gins but no data were available verifying the accuracy of the meter. At the request of stakeholders the unit conducted a three year study of mc measurement by this design of bale mc meter at four gins. Oral and written reports were presented to stakeholders. The manufacturer improved the accuracy of the device after the second year of data was presented. The third year of data verified the improvement. Gin managers now have solid data upon which to evaluate this meter and the meter is currently used by many gins to assure that the final mc of the lint is neither too dry or too near the upper mc limit.
Impacts
(N/A)
Publications
- Hinchliffe, D.J., De Lucca, A., Condon, B.D., O'Regan, J., Clemmons, J., Zeng, L., Byler, R.K., Reynolds, M.L., Allen Jr, H.C., Santiago Cintron, M. , Madison, C.A. 2014. A pilot-scale nonwoven roll goods manufacturing process reduces microbial burden to pharmacopeia acceptance levels for nonsterile hygiene applications. Textile Research Journal. 84(5):546-558.
- Montalvo Jr, J.G., Von Hoven, T.M., Byler, R.K., Boykin, D.L. 2015. Probing bias reduction to improve comparability of lint cotton water and moisture contents at moisture equilibrium. Journal of Cotton Science. pp 194-211.
- Sui, R., Byler, R.K., Fisher, D.K., Barnes, E.M., Delhom, C.D. 2014. Effect of supplemental irrigation and graded levels of nitrogen on cotton yield and quality. Journal of Agricultural Science. 6(2):119-131.
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Progress 10/01/13 to 09/30/14
Outputs
Progress Report Objectives (from AD-416): Our goal is to increase the profitability of the U.S. cotton production system through new and improved cotton ginning equipment and processes resulting in enhanced market value and utility of ginned cotton lint in the global market. We will focus on the following objectives: 1) Refine the design, operation, and management of existing cotton ginning machinery to increase productivity and reduce short fiber content, neps, and seed coat fragments; 2) Improve cotton gin processing by comprehensively investigating the impact of cotton cultivar on fiber quality and non-lint content and develop improved relationships between measurable cotton traits and the value of the final products; 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use; and 4) Optimize the entire ginning system from module to bale, particularly related to air quality issues, energy use, and control of cotton moisture content. Approach (from AD-416): The objectives are interrelated and success in one contributes to success in another. Improved measurement and control will allow better response to changing gin conditions, including those caused by variation in cultivar. Better machinery design and management can be used to respond to these variations in seed cotton. Improved ginning machinery and better measurements of the cotton being processed will contribute to optimization of the entire ginning system. 1) Refine the design, operation, and management of existing cotton ginning machinery. We will test modifications to existing machinery and new machine designs for the three main functions of ginning machines�seed cotton cleaning, fiber-seed separation, and lint cleaning. We plan to develop machinery with adjustable operating parameters for use in control systems to optimize product value and quality. New management strategies will also be tested. 2) Improve cotton gin processing by improving measurement and use of measurements. Three issues will be addressed under this objective: 1) some important properties are unidentified; 2) no technique exists for measuring certain important properties, particularly in real-time at the gin; and 3) analysis using the current variables results in interactions, which may result from not measuring the correct variables or an incomplete understanding of the processes. First, we will simplify the control problem using cotton from a limited number of known cultivars and growth conditions. Second, we will find measurable traits which will allow adjustments to the ginning process for optimal processing of different cultivars, without knowledge of the cultivar. Finally, a control system using these properties will be developed to maximize fiber value and quality, accounting for variation due to cultivar and growth conditions. 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use. Currently, many important properties to gin management cannot be measured accurately, or in real- time at the gin. Sensors will be developed to measure these parameters. Advanced statistical techniques will be used to integrate information from many sensors and develop predictive models. The final step will be to develop a control system using these sensors and logic which will result in improved gin management, as demonstrated by improved fiber quality or more efficient use of resources. 4) Optimize the entire ginning system from the seed cotton module to lint, seed, and byproduct use. Dust emissions from cotton gins will be measured, so that regulatory agencies have accurate data. Energy use will be monitored throughout cotton gins. Systems will be designed that can alert ginners to conditions reducing energy efficiency or automatically conserve energy without negatively impacting gin processing. Improved systems will be designed for controlling drying and moisture addition to improve gin efficiency, product storage, and fiber quality. Work continued examining the different response of different cotton cultivars to cotton ginning processes including energy use per bale. Data with different cultivars was added to the data set. Cotton cultivars related to measurements of cotton hairiness did not predict cotton lint trash levels and ease of cleaning across different geographical areas in the U.S. as well as had been expected based on previous laboratory studies. Even relative hairiness of different cultivars based on past measurements did not correlate as well as expected. Additional data and more complete data were collected in commercial gins regarding energy use per cotton bale produced. Much energy is used in gins when moving cotton by air. Moving materials by air makes gin layout simpler and was inexpensive when energy was relatively inexpensive. In the past the gins used worst-case conditions for air-flow design. Work on reducing the energy use per bale during material transportation by airflow continued and appears promising in reducing energy use for all cotton gins. Work continued with two commercially available measurement devices for cotton bale moisture content. This work had been specifically requested by stakeholders. Data analysis showed that fiber maturity is crucial to ginning fiber which results in better quality yarn, independent of other measures of fiber quality. This knowledge affects certain producers who terminate fiber development early to control micronaire, a measure upon which price is partially determined, and for production in certain areas of the U.S. and for certain years when the environment happens to not be adequate for producing fiber of full maturity. An experimental gin processing system has been designed, many machines and other parts have been purchased, and installation was begun. This system will allow the study of higher capacity systems more similar to the higher capacity commercial gins. Significant progress was made in publishing the study of dust from ginning processes which was completed in cooperation with other ARS units. Sample analysis, data analysis, draft manuscripts, and final manuscripts were completed.
Impacts
(N/A)
Publications
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. First stage mote system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):425-435.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. Second- stage mote system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):436-446.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. Mote cyclone robber system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):468-478.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. Master trash system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):489-499.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. Mote trash system PM2.5 emission factors and rate for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):479-488.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. Mote cleaner system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):457-467.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. First stage lint cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):368-379.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. Unloading system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):309-319.
- Boykin Jr, J.C., Buser, M.D., Whitelock, D.P., Holt, G.A. 2013. Second stage lint cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):380-390.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. First stage seed-cotton cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):320-332.
- Boykin Jr, J.C., Buser, M.D., Whitelock, D.P., Holt, G.A. 2013. Second stage seed-cotton cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):333-345.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. Third stage seed-cotton cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):346-356.
- Whitelock, D.P., Buser, M.D., Boykin Jr, J.C., Holt, G.A. 2013. Battery condenser system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):402-413.
- Hardin IV, R.G., Byler, R.K. 2013. Evaluation of seed cotton cleaning equipment performance at various processing rates. Applied Engineering in Agriculture. 29(5):637-647.
- Byler, R.K., Delhom, C.D. 2013. Evaluation of fiber and yarn quality with and without seed cotton cleaner material produced in a commercial cotton gin. American Society of Agricultural and Biological Engineers. 29(5):621- 625.
- Bechere, E., Boykin Jr, J.C., Zeng, L. 2014. Genetics of ginning efficiency and its genotypic and phenotypic correlations with agronomic and fiber traits in upland cotton. Crop Science. 54:507-513.
- Funk, P.A., Hardin IV, R.G., Hughs, S.E., Boykin Jr, J.C. 2013. Changes in cotton gin energy consumption apportioned by ten functions. Journal of Cotton Science. 17:174-183..
- Boykin Jr, J.C., Buser, M.D., Whitelock, D.P., Holt, G.A. 2013. Cyclone robber system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):414-424.
- Boykin Jr, J.C., Buser, M.D., Whitelock, D.P., Holt, G.A. 2013. Combined mote system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):447-456.
- Boykin Jr, J.C., Buser, M.D., Whitelock, D.P., Holt, G.A. 2013. Overflow system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):357-367.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2013. Combined lint cleaning system PM2.5 emission factors and rates for cotton gins: Method 201A combination PM10 and PM2.5 sizing cyclones. Journal of Cotton Science. 17(4):391-401.
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Progress 10/01/12 to 09/30/13
Outputs
Progress Report Objectives (from AD-416): Our goal is to increase the profitability of the U.S. cotton production system through new and improved cotton ginning equipment and processes resulting in enhanced market value and utility of ginned cotton lint in the global market. We will focus on the following objectives: 1) Refine the design, operation, and management of existing cotton ginning machinery to increase productivity and reduce short fiber content, neps, and seed coat fragments; 2) Improve cotton gin processing by comprehensively investigating the impact of cotton cultivar on fiber quality and non-lint content and develop improved relationships between measurable cotton traits and the value of the final products; 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use; and 4) Optimize the entire ginning system from module to bale, particularly related to air quality issues, energy use, and control of cotton moisture content. Approach (from AD-416): The objectives are interrelated and success in one contributes to success in another. Improved measurement and control will allow better response to changing gin conditions, including those caused by variation in cultivar. Better machinery design and management can be used to respond to these variations in seed cotton. Improved ginning machinery and better measurements of the cotton being processed will contribute to optimization of the entire ginning system. 1) Refine the design, operation, and management of existing cotton ginning machinery. We will test modifications to existing machinery and new machine designs for the three main functions of ginning machines�seed cotton cleaning, fiber-seed separation, and lint cleaning. We plan to develop machinery with adjustable operating parameters for use in control systems to optimize product value and quality. New management strategies will also be tested. 2) Improve cotton gin processing by improving measurement and use of measurements. Three issues will be addressed under this objective: 1) some important properties are unidentified; 2) no technique exists for measuring certain important properties, particularly in real-time at the gin; and 3) analysis using the current variables results in interactions, which may result from not measuring the correct variables or an incomplete understanding of the processes. First, we will simplify the control problem using cotton from a limited number of known cultivars and growth conditions. Second, we will find measurable traits which will allow adjustments to the ginning process for optimal processing of different cultivars, without knowledge of the cultivar. Finally, a control system using these properties will be developed to maximize fiber value and quality, accounting for variation due to cultivar and growth conditions. 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use. Currently, many important properties to gin management cannot be measured accurately, or in real- time at the gin. Sensors will be developed to measure these parameters. Advanced statistical techniques will be used to integrate information from many sensors and develop predictive models. The final step will be to develop a control system using these sensors and logic which will result in improved gin management, as demonstrated by improved fiber quality or more efficient use of resources. 4) Optimize the entire ginning system from the seed cotton module to lint, seed, and byproduct use. Dust emissions from cotton gins will be measured, so that regulatory agencies have accurate data. Energy use will be monitored throughout cotton gins. Systems will be designed that can alert ginners to conditions reducing energy efficiency or automatically conserve energy without negatively impacting gin processing. Improved systems will be designed for controlling drying and moisture addition to improve gin efficiency, product storage, and fiber quality. 1) Work continued on the effects cotton cultivar has on the cotton ginning process especially as cultivar affects final quality. This unit along with others in ARS and outside continued working on the hairiness issue and a hairiness index has been proposed which will allow the producer to better compare cultivars when planting the crop. 2) Work continued with the ginning energy relationship with cultivar. 3) Significant progress was made in publishing the study of dust from ginning processes with other ARS researchers and those outside ARS. Sample analysis, data analysis, and draft manuscripts were completed. 4) Data collection and analysis continued for the study of all aspects of energy use in ginning. Some results were released. 5) Data were collected, analyzed and a preliminary publication prepared regarding the pneumatic conveying of seed cotton. Much energy is used in pneumatic conveying in cotton gins and much of this energy is known to not be strictly required to move the seed cotton; rather the use of pneumatic conveying is convenient for gin design and operation. However, little data has been published regarding the engineering details of pneumatic conveyance of seed cotton. 6) An experimental gin processing system has been designed, many machines and other parts have been purchased, and installation was begun. This system will allow the study of higher capacity systems similar to the higher capacity commercial gins. 7) Based on request from the industry and with financial support from them, work with the measurement of cotton bale moisture content was continued in a commercial gin in TN and the results were similar to what was seen in a different gin in the previous year at a gin in GA. 8) Roller ginning has been used in the arid southwest, especially with pima cotton, and has resulted in fiber with better length quality. Additional data of the roller ginning of upland cotton in the humid Mississippi Delta at different moisture content levels showed that the effects on fiber quality were different than when saw-type gins were used at the same moisture contents.
Impacts
(N/A)
Publications
- Hardin IV, R.G., Funk, P.A. 2012. Electricity use patterns in cotton gins. Applied Engineering in Agriculture. 28(6): 841-849.
- Sui, R., Byler, R.K. 2012. Air-bar cotton lint cleaner. Applied Engineering in Agriculture. 28(2):173-177.
- Von Hoven, T.M., Montalvo Jr, J.G., Byler, R.K. 2012. Preliminary assestment of lint cotton water content in gin-drying temperature studies. Journal of Cotton Science. 16:282-292.
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Progress 10/01/11 to 09/30/12
Outputs
Progress Report Objectives (from AD-416): Our goal is to increase the profitability of the U.S. cotton production system through new and improved cotton ginning equipment and processes resulting in enhanced market value and utility of ginned cotton lint in the global market. We will focus on the following objectives: 1) Refine the design, operation, and management of existing cotton ginning machinery to increase productivity and reduce short fiber content, neps, and seed coat fragments; 2) Improve cotton gin processing by comprehensively investigating the impact of cotton cultivar on fiber quality and non-lint content and develop improved relationships between measurable cotton traits and the value of the final products; 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use; and 4) Optimize the entire ginning system from module to bale, particularly related to air quality issues, energy use, and control of cotton moisture content. Approach (from AD-416): The objectives are interrelated and success in one contributes to success in another. Improved measurement and control will allow better response to changing gin conditions, including those caused by variation in cultivar. Better machinery design and management can be used to respond to these variations in seed cotton. Improved ginning machinery and better measurements of the cotton being processed will contribute to optimization of the entire ginning system. 1) Refine the design, operation, and management of existing cotton ginning machinery. We will test modifications to existing machinery and new machine designs for the three main functions of ginning machines�seed cotton cleaning, fiber-seed separation, and lint cleaning. We plan to develop machinery with adjustable operating parameters for use in control systems to optimize product value and quality. New management strategies will also be tested. 2) Improve cotton gin processing by improving measurement and use of measurements. Three issues will be addressed under this objective: 1) some important properties are unidentified; 2) no technique exists for measuring certain important properties, particularly in real-time at the gin; and 3) analysis using the current variables results in interactions, which may result from not measuring the correct variables or an incomplete understanding of the processes. First, we will simplify the control problem using cotton from a limited number of known cultivars and growth conditions. Second, we will find measurable traits which will allow adjustments to the ginning process for optimal processing of different cultivars, without knowledge of the cultivar. Finally, a control system using these properties will be developed to maximize fiber value and quality, accounting for variation due to cultivar and growth conditions. 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use. Currently, many important properties to gin management cannot be measured accurately, or in real- time at the gin. Sensors will be developed to measure these parameters. Advanced statistical techniques will be used to integrate information from many sensors and develop predictive models. The final step will be to develop a control system using these sensors and logic which will result in improved gin management, as demonstrated by improved fiber quality or more efficient use of resources. 4) Optimize the entire ginning system from the seed cotton module to lint, seed, and byproduct use. Dust emissions from cotton gins will be measured, so that regulatory agencies have accurate data. Energy use will be monitored throughout cotton gins. Systems will be designed that can alert ginners to conditions reducing energy efficiency or automatically conserve energy without negatively impacting gin processing. Improved systems will be designed for controlling drying and moisture addition to improve gin efficiency, product storage, and fiber quality. A survey of seed cotton cleaning in commercial cotton gins showed that some gins regularly exceed the recommended seed cotton cleaner loading. Scaled tests showed that significantly higher processing rates could be used without reducing cleaning performance. Testing in a commercial gin at the recommended maximum rate and double that rate showed some loss in cleaning ability at higher rate. Laboratory analysis of the material removed by seed cotton cleaners from multiple cultivars and locations (processed identically) is ongoing. Roller ginning produces lint with greater fiber length and less short fiber than saw-ginning with Upland cottons in the West. A high-speed roller ginning system was tested with Upland cotton grown in the humid Mid-South and analysis showed an improvement in fiber when using the roller gin line compared to the traditional saw-gin line. Differences in processing for different cotton cultivars have been observed. Because different cotton cultivars respond differently to ginning processes conventional ginning systems do not process all cotton optimally. To quantify these differences the energy and time for ginning a number of genotypes were measured. The energy needed to gin different cotton genotypes was inversely correlated with ginning rate. The cotton variety trials included 10 varieties and 6 locations in 2010, and 10 varieties and 5 locations in 2011. Potential sources of variability in fiber maturity included variety, soil type, weather, irrigation, terrain (hills vs. delta), and other �environmental� factors. Samples were ginned and spun into yarn with standard spinning/yarn data collected. Cotton gins use energy in material transport, processing, and drying. Survey data has shown that the energy used per bale produced varies by over 2:1 even for gins of the same size. Initial analysis of energy use in commercial gins shows that less energy per bale is used when the gin stands are kept fully loaded. Power demand in commercial gins when no cotton is being processed was 2/3 of the fully loaded systems. Electricity use was monitored in four commercial gins during the 2011- 2012 ginning season. Additional monitoring equipment was installed to measure air flow and dryer temperatures at two gins. One gin used 1.45 L/bale for the first stage dryer and 0.32 Liter/bale for the second stage dryer. The other gin required 1.27 Liter/bale for the first stage dryer and did not use the second stage dryer. The effect cotton gins have on air quality and issues in measuring and modeling the effect on air quality are being studied at several locations over several years. These samples and data will be analyzed and results shared with relevant regulatory agencies. Moisture content measurement and control in the gin continues to be a problem for stakeholders. Moisture measurement and management work was expanded, especially in relation to final bale moisture content, and meetings with stakeholders were held for technology transfer. The result of a study of commercially available sensors was presented to several groups of stakeholders and additional work in this area is being planned, based on stakeholder requests. Accomplishments 01 Improvement of cotton ginning through genetics. Ginners have noted for many years that cultivar affects the response of cotton in the different gin machines but no attempt was made to take advantage of genetics to improve gin processing. In this project conducted by ARS scientists from Stoneville, MS, the goal was to reduce ginning energy and increase the ginning rate which will reduce ginning costs. Forty six genotypes were studied and found to vary significantly in ginning energy and ginning ra A sub-set of these genotypes were tested for fiber-seed attachment forc with a pendulum-type tester, and results confirmed attachment force was highly correlated with ginning energy and slightly correlated with ginni rate. These results were published in scientific journals with the conclusion that genotypes varied significantly in "ginning efficiency" d to differences in fiber-seed attachment force. The instrument for measurement of attachment forced was improved and is a measurement more suitable for genotype selection than the measurement of ginning energy o ginning rate which require a substantial supply of seed cotton. Several populations have been developed from genotypes with high and low ginning energy and rate, and the second year of field work is underway to determine heritability and conduct quantitative trait loci (QTL) analysi The basis for genetic development to improve cotton ginning and a simple way of measuring the ginning potential for use by geneticists has been developed. It remains for the geneticists to produce cotton cultivars with the desired traits.
Impacts
(N/A)
Publications
- Whitelock, D.P., Armijo, C.B., Boykin Jr, J.C., Buser, M.D., Holt, G.A., Barnes, E.M., Valco, T.D., Findley, D.S., Waston, M.D. 2011. Beltwide cotton quality before and after lint cleaning. Journal of Cotton Science. 15:282-291.
- Hardin IV, R.G., Searcy, S.W. 2011. Autonomous cotton module forming system. Applied Engineering in Agriculture. Vol. 27(4): 559-568.
- Sui, R., Byler, R.K. 2012. Evaluation of a mass flow sensor at a gin. Journal of Cotton Science. 16:27-33.
- Bechere, E., Boykin Jr, J.C., Meredith Jr, W.R. 2011. Evaluation of cotton genotypes for ginning energy and ginning rate. Journal of Cotton Science. 15:11-21.
- Buser, M.D., Whitelock, D.P., Boykin Jr, J.C., Holt, G.A. 2012. Characterization of cotton gin particulate matter emissions � project plan. Journal of Cotton Science. 16:105-116.
- Delhom, C.D., Byler, R.K. 2011. Performance of a microwave bale moisture content meter. Journal of Agricultural Science and Technology. 5(2):181- 187.
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Progress 10/01/10 to 09/30/11
Outputs
Progress Report Objectives (from AD-416) Our goal is to increase the profitability of the U.S. cotton production system through new and improved cotton ginning equipment and processes resulting in enhanced market value and utility of ginned cotton lint in the global market. We will focus on the following objectives: 1) Refine the design, operation, and management of existing cotton ginning machinery to increase productivity and reduce short fiber content, neps, and seed coat fragments; 2) Improve cotton gin processing by comprehensively investigating the impact of cotton cultivar on fiber quality and non-lint content and develop improved relationships between measurable cotton traits and the value of the final products; 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use; and 4) Optimize the entire ginning system from module to bale, particularly related to air quality issues, energy use, and control of cotton moisture content. Approach (from AD-416) The objectives are interrelated and success in one contributes to success in another. Improved measurement and control will allow better response to changing gin conditions, including those caused by variation in cultivar. Better machinery design and management can be used to respond to these variations in seed cotton. Improved ginning machinery and better measurements of the cotton being processed will contribute to optimization of the entire ginning system. 1) Refine the design, operation, and management of existing cotton ginning machinery. We will test modifications to existing machinery and new machine designs for the three main functions of ginning machines�seed cotton cleaning, fiber-seed separation, and lint cleaning. We plan to develop machinery with adjustable operating parameters for use in control systems to optimize product value and quality. New management strategies will also be tested. 2) Improve cotton gin processing by improving measurement and use of measurements. Three issues will be addressed under this objective: 1) some important properties are unidentified; 2) no technique exists for measuring certain important properties, particularly in real-time at the gin; and 3) analysis using the current variables results in interactions, which may result from not measuring the correct variables or an incomplete understanding of the processes. First, we will simplify the control problem using cotton from a limited number of known cultivars and growth conditions. Second, we will find measurable traits which will allow adjustments to the ginning process for optimal processing of different cultivars, without knowledge of the cultivar. Finally, a control system using these properties will be developed to maximize fiber value and quality, accounting for variation due to cultivar and growth conditions. 3) Improve automated measurement of relevant properties and control of gin processes for more efficient management, especially related to moisture, fiber quality, and energy use. Currently, many important properties to gin management cannot be measured accurately, or in real- time at the gin. Sensors will be developed to measure these parameters. Advanced statistical techniques will be used to integrate information from many sensors and develop predictive models. The final step will be to develop a control system using these sensors and logic which will result in improved gin management, as demonstrated by improved fiber quality or more efficient use of resources. 4) Optimize the entire ginning system from the seed cotton module to lint, seed, and byproduct use. Dust emissions from cotton gins will be measured, so that regulatory agencies have accurate data. Energy use will be monitored throughout cotton gins. Systems will be designed that can alert ginners to conditions reducing energy efficiency or automatically conserve energy without negatively impacting gin processing. Improved systems will be designed for controlling drying and moisture addition to improve gin efficiency, product storage, and fiber quality. Gins clean seed cotton to remove extraneous plant parts and soil. A survey of commercial cotton gins showed that some gins regularly exceed the currently recommended seed cotton cleaner loading. Equipment was constructed that was capable of processing at rates 3x higher than currently recommended. Tests showed that processing rates significantly higher than recommended could be used without reducing cleaning performance. Testing in a commercial gin at the recommended maximum rate and double that rate showed some loss in cleaning ability at higher rate. Roller ginning produces lint with greater fiber length and less short fiber than saw-ginning with Upland cottons in California and Arizona. A high-speed roller gin stand has been installed along with lint cleaning equipment designed for use with roller gins. The equipment has been tested with Upland cotton grown in the humid Mid-South and analysis has shown an improvement in fiber when using the high-speed roller gins stand line compared to the traditional saw-gin line. Differences in processing for different cotton cultivars have been observed. Because different cotton cultivars respond differently to ginning processes conventional ginning systems do not process all cotton optimally. To quantify these differences the energy and time for ginning a number of genotypes were measured. The energy needed to gin different cotton genotypes was inversely correlated with ginning rate. This relationship supports the concept of developing cultivars which require less energy to process and which could produce savings for the ginning industry. Material flow rate is critical in automated control. A prototype system has been constructed and tested which demonstrated that the system indicates fiber flow rates accurately. Discussions are underway with a Cooperative Research and Development Agreement (CRADA) partner for developing a commercial instrument. Cotton gins use energy in material transport, processing, and drying. Survey data has shown that the energy used per bale produced varies by over 2:1 even for gins of the same size. Initial analysis of energy use in commercial gins shows that less energy per bale is used when the gin stands are kept fully loaded. Power demand in commercial gins when no cotton is being processed was 2/3 of the fully loaded systems. Ginners are encouraged to shut down equipment when not ginning, thereby saving energy and reducing costs. The effect cotton gins have on air quality and issues in measuring and modeling the effect on air quality are being studied at several locations over several years. These samples and data will be analyzed and results shared with relevant regulatory agencies. Moisture content measurement and control in the gin continues to be a problem for stakeholders. Additional efforts have been made to expand the moisture measurement and management efforts, especially in relation to final bale moisture content, and meetings with stakeholders have been undertaken for technology transfer. Additional work in this area is being planned based on stakeholder requests. Accomplishments 01 Seed cotton cleaning at increased throughput. Seed cotton cleaning machines have seen increasing throughput over the years without documentation of the effects of higher loading since rates of up to 8.0 bales/hour/meter (bales/hr/m) were documented in 1972. Surveys have indicated that a significant number of commercial gins exceed 14.7 bales/hr/m seed cotton cleaner loading. Seed cotton cleaning machinery capable of processing cotton at rates of over 23 bales/hr/m was assemble at the Cotton Ginning Research Unit in Stoneville, MS. Rates of 6.6 (th currently recommended maximum rate), 9.8, 13.1, 16.4, and 19.7 bales/hr/ were tested in the recommended sequence of cleaning machinery. Experiments have been conducted with two seasons of cotton. Three cultivars from the first season contained little foreign matter (4.6, 5. and 7.2% by weight) and the processing rate had no effect on cleaning performance. Higher processing rates negatively affected cleaning of th other cultivar, which was stripper-harvested and contained 26.4% foreign matter. For the second experiment, cotton with intermediate levels of foreign matter content was tested at two moisture contents. Poorer cleaning efficiency was observed at higher processing rates. No significant seed cotton loss was observed in either test at any processi rate. A processing rate test was also conducted in a commercial gin, comparing processing rates of 6.6 and 13.1 bales/hr/m. Lint leaf grade was improved by 0.4 at the lower rate; however, this difference could be due to improved lint cleaning. The data showed that the processing rate used at most gins did not contribute significantly to increased non-lint content or seed cotton loss with well maintained equipment and verified the acceptability of current practice. 02 High-speed roller cotton gin applied to eastern cotton. Research carrie out with upland cotton by ARS in New Mexico and at a few Western commercial gins has shown that the recently available high-speed roller gin stand (HSRG) produced lint with better properties, especially greate fiber length and lower short fiber content, and higher commercial value than the traditional saw-type gin stand. The operation of the HSRG in t more humid mid-south has not been documented. Work with the HSRG at the Cotton Ginning Research Unit in Stoneville, MS, has shown approximately the same improvement in fiber properties as was observed with the upland cotton grown in the more humid eastern U.S. as was observed in the drier west. Certain cultivars have been shown to gin more easily and others with more difficulty when using the HSRG. Ginning at lint moisture contents higher than those used in the drier west has not resulted in an difficulties. A commercial mill has requested bale sized samples of eastern upland cotton ginned with the HSRG and several commercial gins located in the east have expressed interest in producing commercial quantities of the lint. A Trust Agreement is being developed with the mill and other ARS units to expand this work. Use of the HSRG will produce cotton lint which has better fiber length properties making the fiber more desirable by cotton mills benefitting cotton producers in the eastern U.S.
Impacts
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Publications
- Hardin IV, R.G., Searcy, S.W. 2010. Operator feedback system for the module builder. Journal of Cotton Science. 14:154-163.
- Sjolander, A.J., Thomasson, J.A., Sui, R., Ge, Y. 2011. Wireless tracking of cotton modules. Part II: automatic machine identification and system testing. Computers and Electronics in Agriculture. 75:34-43.
- DDelhom, C.D., White-Ghoorahoo, L.A., Pang, S.S. 2010. Development and characterization of cellulose/clay nanocomposites. Composites: Part B. 41:475-481.
- Boykin Jr, J.C., Reddy, K.N. 2010. The effects of narrow-row and twin-row cotton on fFiber properties. Journal of Cotton Science. 14:205-211.
- Sui, R., Thomasson, J., Byler, R.K., Boykin Jr, J.C., Barnes, E.M. 2010. Effect of machine-fiber interaction on cotton fiber quality and foreign- matter particle attachment to the fiber. Journal of Cotton Science. 14:145- 153.
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