Progress 07/01/18 to 05/31/20
Outputs
Target Audience:The target audiences reached by our efforts to developCoupled Oil-Biochar Production Systems (COBPS) and value-added eastern red cedar (ERC) oil and biochar products during the course of this project have included the following: 1) Great Plains Biochar Initiative (GPBI), including an article in their newsletter, aletterof support from the GPBI to support this project and Phase 2 project including outreach information provided to them and their network, informational requests from a producer recipient of their newsetter; 2) Kansas Forest Service (KFS) and Nebraska Forest Service (NFS)including a letter of support from KFS to support this project and Phase 2 project and updates to them as well as NFS; KFS shared information regarding the production of biochar from ERC with participants at their 2019 Fall Field Day (October 9, 2019; Geyer Research Facility) as well as demonstrated the prototype Kon Tiki Kiln (however, they did not demo the oil distillation process) 3) Kansas Farmers Union (KFU) including a letter of support from their organization to support Phase 2 project and updates to them regarding the project; KFU is a membership organization and the state's oldest active general farm organization; 4) Kansas State Research and Extension including a letter of support to support Phase 2 project and updates to them regarding their project; 5) Kansas State University Technology Development Institute including an informational meeting with them to discuss the technology and identificaiton of manufacturers and co-packaging companieswho may be able to support goal of our Commercialization Plan; 6) Larta Institute including a letter of support for Phase 2 project and agreement to provide TABA services as well as mentoring to develop Commercialization Plan for Phase 2 project; 7) Eurofins Laboratory (Germany) including provision of European Biochar Certificate testing of ERC biochar products; 8) Aromatic Plant Research Center (APRC) including provision of ERC aromatic oil and hydrosol testing and consultation with aromatic oil scientists regarding methods to upgrade ERC oil; 9) Wilson Biochar, LLC including outreach and consultation with Kelpie Wilson, lead biochar scientist, at Kansas Biochar Workshop training sponsored by the Kansas Forest Service; 10) Identification of two potential land owners (1 farmer, 1 rancher) with interest in becoming a Blue Earth Biochar Co-operator (purchase and operate COBPS from Blue Earth and produce ERC oil and biochar per Blue Earth specifications) as part of Phase 2 and Commercialization Plan; 11) Outreach to three local/ regional horticultural businesses, with two indicating interest in sale of value-added biochar soil amendments. Phase 2 proposed objectives buildion outreach to the aforementioned target audiences to support further development of the COBPS, its valued-added ERC oil and biochar products, and assist in development of a co-operator network in Kansas (and eventually other states in the central U.S.) to utilize the COBPS and its VA product formulations as part of small and rural business development. In our Phase 2 proposal and commerciailzation plan we outline and further describe the following target audiences: existing ERC removal operators, farmers, ranchers, and rural land owners integrated into an alliance with government agency and conservation interests, extension and state forestry agencies, biochar initiatives and membership-based farmer, and rancher and permaculture groups. We also describe the end-users of our products there and the market segment we intend to reach. Changes/Problems:Multiple challenges were encountered during the Phase 1 Project. These challenges had to be overcome in many cases to complete the project. Additional challenges may need to be overcome in the future to improve the COBPS design and its application to produce value-added ERC oil and biochar efficiently and effectively, as part of a commercially viable business and co-operator network. The main challenges to be overcome to complete the project included the following: Drying of oil-extracted ERC chips: ERC chips during early trials were dried outdoor by the sun. However, Blue Earth did not have a concrete pad on which to dry the chips. ERC chips were dried on a hard dirt road but were subject to contamination with clay and limestone dust as they were mechanically rotated with a skid steer to accelerate solar drying. The dust made the chips much harder to pyrolize and this resulted in occasional trial failures. Blue Earth utilized galvanized metal roofing on which to dry chips to overcome the immediate challenge of dust contamination. Additionally, delays were often encountered due to inclement weather which delayed chip drying (e.g., rain), adversely affecting work flow. Future solutions would be either to construct a concrete pad on which to dry chips, with protection from rain (e.g., clear roof or tarp system) or to modify COBPS design to better utilize dry heat from the gasifier to dry a third batch of chips in a weather-protected bin as part of the work flow. Boiler warping: During the COBPS trials, the boiler experienced some warping and an eventual leak. The challenge was overcome simply by rewelding the boiler. However, in the future, a double walled boiler may be more effective so that the bottom metal is not directly subjected to the high heat and flame. Heat generated between the exposed metal and the boiler metal could potentially be used to dry oil-extracted ERC chips for next batch cycle. Distiller corrosion: The distillation of ERC bio-oil seemed to partially corrode the steel of which the distiller unit is constructed. This is only a minor problem, but could be overcome utilizing stainless steel. However, stainless steel construction would increase the cost of production (i.e., cost of goods sold). An alternative solution may be to coat the interior of the distiller with ceramic coating or another coating material. Distiller cooling/ temperature retention: During the early phases of COBPS trials, the lid of the distiller experienced some cooling due to wind exposure. This resulted in the inability to maintain a temperature close to 100o C and reduced the ERC oil output. This challenge was overcome using fiberglass insulation applied to the boiler lid. A future solution may be related to (3) where a ceramic coating is applied, or perhaps a double wall including an interior wall of stainless steel is utilized. The main challenges to be overcome in the future to improve design and application of the COBPS included the following: ERC bio-oil losses: ERC bio-oil was not all captured as part of the COBPS trials. As part of the current COBBS design (final design used in COBPS trials), heat from the gasifier was blown into the distiller unit with an attic fan. However, as the boiler exceeded temperatures of 175o C, the distiller unit became somewhat pressurized and ERC oil was lost as it vented back against the fan. These ERC bio-oil losses may be as high as 50% of the potential production. While reasonable extraction efficiencies of 30-60 gallons of bio-oil hydrosol per 100 ft of ERC chip inputs were achieved, a solution to the bio-oil vapor lost through the fan is highly recommended. One solution is to simply remove the fan, as long as total bio-oil production is not compromised due to less heat provided to the distiller; this fan could be repurposed to dry wood chips as in (1) above. Another solution would be to utilize a much higher capacity fan that can overcome back pressure of the steam in the distiller. Finally, a synthetic solution may be to repurpose the fan for chip drying as in (1) above while also creating a passive heating pathway that heats the entire distiller vessel (e.g., double wall around distiller that allows passive heat transfer from a double walled gasifier unit or boiler unit). Air to Gasifier: A one-speed, 24-inch diameter attic fan was utilized to blow air into the gasifier unit. However, adjustable and increased pyrolysis temperatures to fuel the bio-oil distillation could be achieved by a multiple-speed, higher capacity fan. Future design should include an adjustable-speed, higher capacity fan to increase air flow through the ERC chip matrix to better control the temperature of the pyrolysis front. As was realized during COBPS trials, the chip matrix is relatively compact making adjustable air flow with greater capacity necessary to achieve a range of optimum conditions based on optimum COBPS outputs of oil and biochar. ERC biochar concentrations of total PAHs (16 priority PAH pollutants): Currently, without incorporation into a soil amendment formulation (i.e., 2/3 dilution with compost and loam), biochar produced using ERC slightly exceeds the highest quality biochar standards (IBI, EBC) for total PAHs. High concentrations of naphthalene and phenanthrene contribute most significantly to the total PAH standard, however they are not considered as PAHs with a carcinogenic toxicant equivalency standard applied to them (i.e., they are less harmful PAHs than once with a toxicant equivalency factor) but as a priority pollutant. PAHs with a toxicant equivalency factor standard, such as benzo(a)pyrene. have low to very low concentrations in the ERC biochar produced by the COBPS. Dilution in soil amendment formulations would reduce the level of total PAHs below the IBI- and EBC- biochar standards. A more conservative approach would be to also produce biochar from deciduous hardwoods or softwoods and mix this with the ERC biochar prior to incorporation into a soil amendment formulation. This protocol could be incorporated into the COBPS design where every other batch of wood chips used to fuel the gasifier was produced from another wood source other than ERC. Very little alteration to the current COBPS batch process would be necessary and the deciduous wood supplied to the gasifier could be used to dry oil-extracted ERC chips for the next batch process. Direct marketing of ERC bio-oil hydrosol products, without separation of high quality components: ERC bio-oil was produced and reported to be of high quality when tested, but it was tested as part of a hydrosol matrix (i.e., mixed with water). Much of the cedrol contents (i.e., marketable constituent of ERC bio-oil produced in high percentage in our trails) stays dissolved in water and is difficult to extract efficiently from the water component. Utilization of the ERC bio-oil hydrosol directly as a primary value-added product, rather than post-processing it to separate out the water, especially if similar price point can be achieved as ERC bio-oil, may be a grand solution without requiring additional non-value-added labor or equipment to achieve it. Market opportunities may include direct use as an insect repellant, a homeopathic deodorant, perfume or cologne, air freshener, or as an anti-fungal medicine (e.g., athlete's foot). What opportunities for training and professional development has the project provided?The project provided an opportunity to support and collaborate with theGreat Plains Biochar Initiative (GPBI), attend a biochar workshop and consult with a national leader in the field of biochar (Wilson Biochar LLC), directly connect with theKansas State University Technology Development Institute to further discuss the technology development and identificaiton of manufacturers and co-packaging companieswho may be able to support goal of our Commercialization Plan, significant mentoring from Larta Institute to develop a viable Commercialization Plan and identify business needs, and connect with leading laboartories such as Eurofins Laboratory (Germany) and Aromatic Plant Research Center (APRC) including consultation with aromatic oil scientists regarding methods to upgrade ERC oil; How have the results been disseminated to communities of interest?Results are currently being summarized and integrated into a website. As part of the Commercialization Plan, and/or completion of Phase 2 objectives if awarded, research and demonstration results will be transformed into marketing materials for dissemination. Likley, these marketing materials would be disseminated through Blue Earth participation in field days, workshops and on-site tours to potential Co-operators. Additionally, marketing materials referencing value-added (VA) oil and biochar product quality and performance would be disseminated through pontential retailers to acquireproduct placement as well as to end-users who buy the VA products from the retailers (i.e., product information attached to the product once it has been placed). What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
Of major importance to the Phase 1 project was exploration of COBPS design specifications based on a range of testing (O.1) and redesign to achieve appropriate batch timing, temperature regulation and extraction efficiencies per batch cycle (O.3) to accomplish (O.2), (O.4)-(O.8). Three iterations of the design were assessed based on lessons learned with a prototype Kon-Tiki biochar kiln and distillation equipment. The final design (Figure 1) varied significantly from the prototypes considered based on valuations of costs, benefits, efficiency, and value stream mapping. Table 1 summarizes analysis conducted to achieve O.3 (systems redesign for final testing) integrating lessons from all COBPS trials related to biochar quality and oil production and also to achieve O.5 and O.7. The economic inputs per return aspect of O.5 have been further integrated into the CP and development of Blue Earth's business strategy for the COBPS and generation of profitable, marketable VA products, in the most material-, price-, labor-, design- and process- efficient manner per outcomes of Phase 1 Work Plan objectives. D COGS % D Price % D Steel % Considerations Design 1 +46.6 +42.4 +19.4 Requires conveyer & auger equipment to handle chips in addition to moderate steel inputs Design 2 +75.6 +71.4 +46.1 Requires conveyer and auger equipment to handle chips, & greatest steel and other material inputs Design 3 - - - Does not require conveyor or auger since chips all input at onset, lowest steel, equipment and materials inputs D VA % D NVA % Efficiency % Considerations Design 1 +2.6 +153.8 54.8 Open fire=safety issue, height=safety issue & inconvenience, no replumbing after batch cycle, least adaptable to Phase 2, most lost heat & gas Design 2 +5.1 +138.5 56.9 Open fire=safety issue, distillation cap movement= safety issue & inconvenience, replumbing after batch cycle, moderately adaptable to Phase 2, lost heat & gas Design 3 - - 75.0 Contained fire & ground level operation = increased safety, replumbing after batch cycle, no lost heat & gas, fully adaptable to Phase 2 Table 1. Estimated % increase in Cost of Goods Sold (COGS, i.e., manufacturing costs), Retail Price, Steel used in construction, Value-added processes & labor (VA), and Non-value added processes and labor (NVA) based on consideration of different COBPS designs using Value Stream Mapping. Overall Process Efficiency is also presented. Design 3 is the simplest, most efficient and cost effective of the COBPS designs evaluated and was developed through the iterative design process made possible through SBIR Phase 1 funding and testing of the COBPS. Since Design 3 was also the least expensive based on both COGS and Retail Price, required least Steel and material inputs, required least VA and NVA labor and processes, and achieved the highest Process Efficiency (75%), the design was used as the basis of comparison to the other designs evaluated. Design 3 is also the design utilized for final testing and delivery of SBIR Phase 1 project objectives and is the only design fully adaptable to delivery of Phase 2 objectives related to proposed COBPS refinements, testing and experimentation. Results of Phase 1 Project are summarized in Figure 3 and Table 2. Identification of sustainable marketing opportunities for VA oil and biochar product lines (O.6) were identified in Phase 1 and have been integrated into the research and development experiments, demonstrations and market placement objectives of the Phase 2 Work Plan and also highlighted in Background and Rationale and Potential Post Application sections of the Phase 2 Grant Application, specifically detailing fast-growing and near-future markets for biochar and upgrading of the value chain for bio-oil hydrosols. One batch process of the COPBS produces 48-96 cu ft of high quality biochar, yielding 144-288 cu ft of biochar soil amendment (1 biochar: 1compost:1 loam ratio) and 30-60 gallons of bio-oil hydrosol. The biochar generated from the COBS using ERC inputs after oil extraction would meet premium grade biochar standards according to IBI- and EBC- methods for all parameters except for concentrations of total PAHs, where naphthalene and phenanthrene contribute most significantly. The biochar does pass the IBI- and EBC- standards for PAH toxic equivalency. Further refinements will continue to reduce total PAHs in final biochar SA formulation. Such refinements may include incorporating batches of deciduous wood chips into every other batch cycle, or mixing of additional components to the biochar such as loam and compost would dilute the soil amendment formulation to meet the biochar production standards. Bio-oil hydrosol characterization indicated that approximately 3-8 gallons (10-13%) of the 30-60 gallons of ERC bio-oil hydrosol could be utilized as an essential oil or component of another VA ERC oil product and 87-90% as a ERC hydrosol product. Scientists at the Aromatic Plant Research Center indicated ERC bio-oil hydrosol distilled from the ERC chips was of high, marketable quality based on its high cedrol content (30-32%); other major constituents were of market value as well. Development of VA hydrosol products from ERC oil distillation process was identified as an important R&D opportunity in Phase 2 since it exceeds 87% of distillation outputs from the bio-oil, with a range of potential applications including products such as insect repellants, fragrances and anti- microbial or fungal uses. An extensive list of potential, local and regional metal fabricators was identified to produce the COBPS (> than 100). Based on the Final Design #3, the COGS for the COBPS is relatively inexpensive (O.5, O.8), in which a co-operator/ buyer could achieve a return on their investment in less than a year. As part of Blue Earth's CP and business strategy to build a network of COBPS co-operators generating VA products under the Blue Earth umbrella, patented COBPS equipment would be supplied to co-operators as part of a start-up at near the COGS price, emphasizing business development by co-operators around patented, VA product formulations. Based on outcomes of Phase 1 Project objectives, analysis of results and integration into CP, business model and Phase 2 Project objectives, the technical feasibility of utilizing the COBPS final design to generate VA product formulations for biochar and bio-oil is promising and sustainably profitable. Key to the success of the CP, and implementation of business model during and after the Phase 2 Project, will be testing and demonstration of VA product formulations to achieve retail market placement and advancing profitable VA products from COBPS outputs and by-products.
Publications
- Type:
Websites
Status:
Published
Year Published:
2019
Citation:
Eastern Red Cedar (ERC) Biochar & Oil Production website: https://sites.google.com/view/erc-biochar-oil-production/home
* website also partially funded by the Great Plains Biochar Iniatitve; summary of the Coupled Oil Biochar Production System was highlighted on website and research data from Phase 1 is being summarized for inclusion at: https://sites.google.com/view/erc-biochar-oil-production/coupled-erc-oil-extractor-biochar-production-system?authuser=0. The website will be transformed to a applied research and marketing approach as Phase 1 project summarized and as part of Phase 2 project and Commercialization Plan if funded.
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