Phosphate-Bonded Fiber and Waste Residual Composites for Applied Commercialization

EPA Grant Number: EM833314
Title: Phosphate-Bonded Fiber and Waste Residual Composites for Applied Commercialization
Investigators: Mueller, Mark J. , Donahue, Patrick K.
Institution: Wisconsin Business Innovation Corporation , Natural Resources Conservation Service
EPA Project Officer: Lasat, Mitch
Project Period: October 1, 2007 through September 30, 2010
Project Amount: $240,200
RFA: Targeted Research Grant (2007) Recipients Lists
Research Category: Targeted Research


The overall objective is to demonstrate technology to produce more durable and environmentally friendly phosphate-bonded waste pulp and paper mill residue composite building products by conducting the necessary technical and business/market development tasks to bring the product concepts to commercialization.


The feasibility of producing laboratory bench-scale building products has already been demonstrated by the project partners. Therefore, the first year of this project will be devoted to refining the previously-developed formulations. We will also conduct market development and market assessment activities. During the second year, medium- and pilot-scale trials will be conducted in conjunction with business and logistic feasibility analyses. During the third year, the focus will be on further pilot-scale testing, energy economics of production, and quantification of the environmental and economic benefits for the industry and consumers.

Expected Results:

We expect to prove the technical and economic feasibility of producing phosphate-bonded waste pulp and paper mill residue composite building products. These products will be tested on a commercial scale and tested to relevant industry performance standards. Overall project performance will be evaluated based on costs and potential profit margins for products developed from low-grade natural fibers compared to those produced from virgin raw materials.

Supplemental Keywords:

Energy efficiency, cold-setting, rapid-setting, acid-base, inorganic binder, slurry, sludge, organic fibers, cellulose, clay, dye, fiber aspect ratio, fire door, door core, fire-resistant panel, durable panel, construction panel, building panel, metal oxide, acid phosphate, iron oxide, calcium oxide, phosphoric acid, particle size, modulus of rupture, modulus of elasticity, screw holding, internal bond, water absorption, thickness swell, viscosity, clean technologies, recycling, reuse, innovative technology, waste reduction, waste minimization,, RFA, Scientific Discipline, TREATMENT/CONTROL, Sustainable Industry/Business, Sustainable Environment, Technology, Technology for Sustainable Environment, Chemistry and Materials Science, clean technologies, pulp, environmental sustainability, green building design, alternative building technology, alternative materials, environmentally friendly green products, construction material, resource recovery

Progress and Final Reports:

  • 2008
  • 2009
  • Final