Grantee Research Project Results
Final Report: High Performance Products for Poultry Biowaste Processing
EPA Contract Number: EPD06027Title: High Performance Products for Poultry Biowaste Processing
Investigators: Skinner, Richard D
Small Business: Production Specialties, Inc.
EPA Contact: Richards, April
Phase: I
Project Period: March 1, 2006 through August 31, 2006
Project Amount: $70,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2006) RFA Text | Recipients Lists
Research Category: Biology/Life Sciences , Small Business Innovation Research (SBIR) , SBIR - Animal Waste and Waste to Energy
Description:
The objective of this research project was to test the technical feasibility of producing a refined lignin product from ligno-cellulosic materials derived from manure and litter feed stocks, and to evaluate the refined lignin as an additive in asphalt pavement formulations. An economic analysis of the commercialization potential of the technology also was a primary objective of the project. The quality of the lignin product and how the quality may be affected by process conditions were key factors in determining the cost of production and the market value of the product.
Biomass from poultry production operations was separated using a variety of physical, thermo-chemical, and biological processes to produce crude lignin materials in a laboratory-scale operation. These samples were refined using a variety of physical and chemical methods to produce a high-purity lignin product. Using laboratory-scale equipment specifically designed to evaluate asphalt pavement quality and durability, a number of asphalt/lignin blends were tested to estimate the beneficial affect lignin might have on asphalt pavement life.
An independent organization evaluated the market potential of the refined lignin product, assuming a commercial-scale operation would deliver a refined lignin at competitive costs, and that the commercial product would confirm the increased pavement life span projected by the laboratory tests.
Summary/Accomplishments (Outputs/Outcomes):
Production of the crude lignin from two simulated process streams was straight forward; the production of the refined lignin from these sources, however, was difficult. The refining process was constrained by the temperature limitations suggested by Production Specialties, Inc.’s project partner. The refined lignin appears to give asphalt an oxidation stability up to concentrations of 7 wt%. The oxidation stability is projected to extend the life of asphalt pavement by 3 to 5 years.
During preparation of the refined lignin samples, new process strategies were devised that would eliminate a number of process steps. Because of time limitations and financial resources, these new strategies were not used. This new approach to refining, however, would eliminate several process steps and would facilitate a “continuous” refining rather than “batch mode” commercial operations. Both of these factors would contribute to significant process simplification and lower production costs in a commercial operation. After the Phase I Small Business Innovation Research (SBIR) project and before the start of a possible Phase II SBIR project, Production Specialties will conduct additional work on the new, more expedient refining strategy, at the company’s expense.
Economic analysis of the market place product value was conducted by an independent organization us ing information, data, and product goals from the project to survey members of the asphalt paving industry. Based on the industry responses, the independent organization provided a strategy and estimated market price for the product, which assumed that the quality of the commercial product would provide the projected life span estimate.
Conclusions:
The production of refined lignin from poultry litter is technically feasible. There are a number of process steps required, using the procedures employed in the laboratory study, to generate the refined product. A new process strategy, however, would be employed to make the product in a commercial operation, which would eliminate several process steps and minimize production costs. The refined lignin is projected to extend the useful life of asphalt pavement by 3 to 5 years.
The paving industry is ready to accept the additive if laboratory and demonstration tests on the commercial product confirm the life span estimate based on the preliminary laboratory work. The projected price for the additive would provide a premium over known alternative uses of the by-product from the proposed poultry litter processing facility. The price premium appears to be sufficient to support the capital and operating costs of making the refined product, although these cost estimates are very preliminary.
The prospect of making a new, high-value product from poultry litter gives added incentive and improves the overall chances of commercial success with the poultry waste processing facility.
The potential commercial impact of this research project is quite large; annual asphalt consumption in the United States is 30 million tons. It is possible that use of refined lignin from these biomass resources could displace 10 percent of this amount, or 3 million tons per year. The useful life span extension would save the U.S. taxpayer $2 billion annually by reducing maintenance by about one-third. Also, the balance of trade would be improved by as much as $600 million because of the amount of foreign crude oil product displaced by biomass-derived products.
The overall environmental and economic impacts of a successful Phase II project are quite compelling. The technology offers green house gas emission reductions, surface water quality improvements, improvements in the nation’s balance of trade, and resolution/mitigation of environmental impacts associated with concentrated animal feeding operations.
Journal Articles:
No journal articles submitted with this report: View all 1 publications for this projectSupplemental Keywords:
small business, SBIR, biowaste processing, petroleum, poultry production, animal waste management, waste reuse, asphalt maintenance, biorefineries, economics, waste processing plants, EPA, sustainable environment, agricultural by-products, animal waste, asphalt emulsions, biowaste, environmentally benign alternative, water, watershed, biomass, renewable, agriculture, recycle, waste,, RFA, Scientific Discipline, TREATMENT/CONTROL, Sustainable Industry/Business, Environmental Chemistry, Sustainable Environment, Technology, Technology for Sustainable Environment, Environmental Engineering, asphalt emulsions, bioengineering, agricultural byproducts, animal waste, alternative materials, biotechnology, biowaste, poulty waste asphalt additiveThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.