Grantee Research Project Results
Final Report: Phosphate-Bonded Fiber and Waste Residual Composites for Applied Commercialization
EPA Grant Number: EM833314Title: 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: Aja, Hayley
Project Period: October 1, 2007 through September 30, 2010
Project Amount: $240,200
RFA: Targeted Research Grant (2007) Recipients Lists
Research Category: Targeted Research
Objective:
The overall goal was 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.
- This overall goal was being pursued with the following objectives:
- To determine manufacturing costs and economic feasibility of producing the newly-developed products.
- To determine whether or not the proposed products meet industry performance standards and consumer acceptance tastes.
- To develop business and logistic models that will establish financial resource requirements and production feasibility on a case-by-case basis.
- Demonstrate the performance of commercial-scale products.
- Transfer the technology to industry.
Summary/Accomplishments (Outputs/Outcomes):
Executive Summary of Project Results
In this project, we have proved the feasibility of producing more durable and environmentally-friendly waste pulp and paper mill residue composite building products from inorganic binders. The original work plan was to utilize magnesium phosphate binders as the binding agent; however, due to rapidly-escalating costs for the phosphate component of the binder, monopotassium phosphate (KH2PO4), we shifted our focus to more cost-effective alternative binders. In this case, we chose magnesium oxychloride (MOC) binders. These binders exhibit properties similar to phosphate binders, but at lower costs. They also have high fire resistance, abrasion resistance, do not need wet/heat curing, and have high compressive strengths.3
We successfully prototyped composite building panels from the MOC binders and waste paper mill residues and completed a range of performance tests according to industry standards; the performance tests included screw holding strength, compressive strength, corrosion resistance, and fire resistance. The prototypes were then shared with panel manufacturers in the building products industry.
Based on industry feedback, we determined that our prototypes have the best opportunity to be used as fire-rated components (stiles, rails, cores, and blocking) for the manufacture of fire-rated doors. We have developed relationships with key fire-rated door manufacturers and shared our prototypes and test results. We are currently negotiating a research agreement and technology licensing deal with one door manufacturer that wishes to potentially use our technology. We are also in discussions with two other door manufacturers that wish to potentially utilize our technology. Thus, the transfer of this technology is currently being conducted.
Significance of Results to the Field
The technology developed in this project is significant to the door manufacturing industry because it provides a more environmentally-friendly alternative to the mineral-based fire-rated components that are currently used. Our products require less energy to manufacture than the state-of-the-art and they utilize two high-volume industrial waste streams (fly ash from coal-burning power plants and waste pulp and paper mill residues), thus reducing the amount of industrial wastes sent to landfill.
Specifically, the selection of MOC binders for this project is significant to the field of building product development because they are less expensive than magnesium phosphate binders, bond very well to a variety or organic and inorganic additives/fillers, and exhibit very high compressive strength and abrasion resistance. In addition, MOC binders appear to have a much higher open time, thus allowing greater ease of product formulation. They also utilize either hard-burned or light-burned magnesium oxide (MgO), which is less expensive and less energy-intensive than the dead-burned MgO used in magnesium phosphate binders. Finally, as with magnesium phosphate binders, MOC binders set at room temperature in the presence of water; thus, the waste residues do not have to be dried prior to sample fabrication.
Relationship of Project Results to the Goals of the Award
The results of this project have allowed us to reach our goal of producing environmentally-friendly pulp and paper mill residue composite building products. The technical work has been completed, research results have been presented to national audiences, and potential business partners have been identified and negotiations are underway to transfer this technology to industry.
Each year, millions of tons of waste pulp and paper mill residue are landfilled, land spread, or burned. The residue is a by-product of pulp and papermaking and consists of short cellulose fibers, clay, calcium carbonate, water, and small amount of various inorganic fillers. The U.S. produces approximately 8.2 million wet tons per year, and Wisconsin generates approximately 572,000 wet tons per year. The underlying driver of this project was the paper industry’s critical need to develop value-added products from the residue and to substantially reduce or eliminate a waste disposal problem. The majority of residue is landfilled, but environmental regulations prevent new landfills from being sited as quickly as existing ones are being filled, making innovative waste disposal solutions more critical every day. As landfill tipping fees rise and land spreading is similarly restricted, the paper industry will turn to the next cheapest treatment – incineration – which will only increase the energy costs of residue disposal. Additionally, the new products are sustainable. They should perform better or equal to conventional products, take much less energy to produce, and have minimal environmental impact. Accordingly, U.S. companies will benefit from reduced production and environmental costs and derive higher margins from the added beneficial properties delivered by the new products.
Conclusions:
We believe this technology can be applied to different pulp and paper mills as the MOC binder is tolerant of feedstock variations. However, slight adjustments to the product component ratios may be needed to produce the best possible product specific to each mill. And commercial production of the new products will divert, potentially, several hundred thousand tons of waste residues from landfills each year. In addition to these near-term results, the project also provided substantial baseline technical data on the development of other inorganic-bonded fiber composites, outside of the door manufacturing industry, using an array of woody and agricultural reinforcing fibers. In fact, the work in this project allowed us to secure funding for a new project that focuses on developing inorganic-bonded wood-based building panels.
Journal Articles:
No journal articles submitted with this report: View all 2 publications for this projectSupplemental 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, alternative building technology, environmental sustainability, green building design, pulp, alternative materials, environmentally friendly green products, construction material, resource recoveryProgress and Final Reports:
Original AbstractThe 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.