Grant Information
| Knowledge Area | Subject of Investigation | Field of Science | Percent |
|---|---|---|---|
| 511 - New and Improved Non-Food Products and Processes | 1820 - Soybean | 2000 - Chemistry | 60% |
| 402 - Engineering Systems and Equipment | 6050 - Communities, areas, and regions, including states and their institutions and organizations | 2020 - Engineering | 40% |
Soylei Innovations (SLI), a limited liability company registered in the State of Iowa operating a Bioproducts Research Facility at the Iowa State University (ISU) Research Park, will scale three related bioproducts for use in the asphalt construction industry derived from poly(acrylated epoxidized high oleic soybean oil) (PAEHOSO), an agricultural commodity-based thermoplastic:P1: BioMAGâ„¢-EasyPAVE, a PAEHOSO emulsion applied to 100% reclaimed asphalt pavement (RAP) millings to facilitate the construction of new asphalt pavements without the need for heat or virgin raw materials at a drastically reduced cost compared to hot mix asphalt (HMA) or concrete. Such cold recycled pavements will reduce the proliferation of RAP waste piles while improving transportation infrastructure, especially in historically underserved low-income rural and urban communities.P2: BioMAGâ„¢-Fog'N'Fix, a rejuvenating and sealing PAEHOSO emulsion applied to existing asphalt pavement surfaces to extend their service life. Unlike incumbent asphalt emulsion products,BioMAGâ„¢-Fog'N'Fix will minimize traffic disruption with rapid penetration into the pavement pore structure, preserving traffic markings and skid resistance on the pavement surface.P3: BioMAGâ„¢-EasyPMAC, a rejuvenating polymer modifier for high-traffic HMA pavements with high RAP content for reductions in cost, waste, energy usage, and emissions generation. Incumbent SBS-modified asphalt must be produced at specialized asphalt terminals and interacts poorly with RAP. Conversely, this bioproduct and be added at the asphalt plant, freeing contractors to formulate HMA that saves cost and increases RAP utilization.SLI will scale up: a chain transfer agent (CTA), an ingredient in PAEHOSO manufacturing (40kg,P1-3); BioMAGâ„¢-GlyTeX, a PAEHOSO-based surfactant that stabilizes BioMAGâ„¢ emulsions with micron-scale particle size (1000 kg,P1-2); and polymer compounding required to transform PAEHOSO to a granular state (5000 kg,P3). Collaborator CHS Inc will supply epoxidized soybean oil feedstocks(up to 100 ton/d), and ACS Technical Products will develop the capacity to make up to 30 ton/d PAEHOSO using CHS/ SLI inputs. SLI and ISU will optimize BioMAGâ„¢ product formulations; NCAT and ISU will conduct TEA and LCA analyses of the bioproducts. SLI and Colorbiotics (CB) will collaborate to upgrade PAEHOSO to finished emulsions (100 tons each). SLI, CB, and NCAT will collaborate with stakeholders to demonstrate the products in pilot construction/maintenance projects, make head-to-head comparisons with incumbent products, and develop verified Environmental Product Declarations. SLI and NCAT will evaluate treated pavement lifetimes through accelerated wear tests. These activities will advance the development of cost-competitive bioproducts with environmental benefits compared to incumbent products, aligned with the 10 Bioproduct Pilot Program priorities.
Chain Transfer Agent Scale-Up- OXCARTSoylei's intensification and scaling efforts will increase this to reduce capital equipment, energy costs, and waste disposal.The short reaction time of each step makes a continuous process attractive from which SoyLei will develop pilot-scale OXCART manufacturing. A continuous process promises lower capital cost, production stability, reduced waste, and reduced operator involvement. Even with a very conservative 60-minute residence time, no more than 600 mL continuous stirred tank reactors will produce the requisite 40 kg in less than 200 hours of operation.BioMAG-GlyTeX (BMG)-PAEHOSO copolymer biosurfactant Scale-upISU has demonstrated, using RAFT polymerization, that a 20 kDa PAEHOSO-based copolymer surfactant can be synthesized and used as the sole surfactant required in the varying emulsion formulations at application rates as low as 0.1 wt %. These macromolecular surfactants, termed BMG enable BioMAG-EasyPAVE (P1) and BioMAG-Fog'N'Fix (P2) mean particle sizes of approximately 1 micrometer with shelf stability of at least 4 months at 90 °F.ISU BMG synthesis employs the Poly100 1-pot 0-waste 0-VOC process technology with Polysorbate 80 as the functional biobased solvent. Using RAFT, the molecular weight can easily be controlled along with the copolymer composition, facilitating optimization of the hydrophilic-lipophilic balance (HLB) and effectiveness of the surfactant.Tensiometry will be used to measure surface tension vs. concentration to determine the critical micelle concentration. Collaborating with ISU, P1 and P2 prototypes at the 1L scale will be evaluated via microscopy and laser diffraction particle size analysis as functions of shear energy, surfactant concentration, solids loading, and time.The biosurfactant scale-up will take place using a succession of 10L, 50L, and 200L vessels at Soylei's Bioproducts Research Facility. Reaction progress will be monitored through in-line viscometry and confirmed with time-series aliquots analyzed by Nuclear Magnetic Resonance (NMR) and Gel Permeation Chromatography (GPC). Reaction sequencing, including semi-batch additions of initiator, will manage heat generation and proper control over the reaction.P1 and P2 product Development and Scale-UpP1 is a high molecular weight polymeric sealer (PAEHOSO) and rejuvenator (SESO) dispersed in water as an emulsion. Water can provide effective mass transport to RAP particles allowing for compaction.Waterborne crosslinking agents will be introduced to accelerate curing. With optimized surfactant formulation, P1 will be mixed with RAP at various emulsion concentrations and application rates and then lab-compacted with a gyratory compactor to form CR pavement samples.Samples will be evaluated according to AASHTO M140 (emulsions) and M316 (polymer modified asphalt emulsions) specifications. Once cured, specimens will be tested using fracture-mechanics based tests that induce crack propagation, including uniaxial tensile strength, disk compact tension, disk-shaped compaction (DCT), IDEAL-CT, Illinois Flexibility Index Test (IFIT), push-pull fatigue, Marshall Stability Test, and indirect tensile strength (IDT).Soylei and ISU will test P1 prototypes in local parking lots or other small test sites. RAP will be placed and sprayed with P1 before compaction; density measurements will track compaction. Core samples will be extracted over time to track curing and longevity. Vehicles will also be driven over the CIP pavement to determine the maximum vehicle weight the CIP pavement can withstand without damage.P2 prototypes with various surface tension modifiers will be screened via contact angle measurements on asphalt-binder coated surfaces and selected to maximize wettability. Soylei will optimize the emulsion milling process parameters to minimize mean particle size.ISU will then use optimized P2 formulation to treat laboratory compacted pavement samples at various solids concentrations, application rates, and pavement temperatures. Emulsions will be evaluated according to AASHTO M140 and M316 specifications. Absorption rates of the treatment will be measured to assess the number of active ingredients delivered. The lipophilic fluorescent dye will be added to the P2 oil phase to visualize the product penetration into the asphalt surface layer (i.e., vertical pavement cross section). Thin asphalt layers will be cut parallel to the surface (i.e., horizontal pavement cross sections), and asphalt binder will be extracted from the thin layers to measure rejuvenation performance. Rheological measurements on the extracted asphalt will provide PG-grade data as a function of pavement depth. A local parking lot application will be conducted, and core samples will be analyzed temporally to confirm laboratory results.To produce 100 tons of P1 and P2 Soylei and Colorbiotics will produce the scale-up quantities of emulsion in 2000-gallon vessels equipped with emulsions impellers. The product will be stored in 230-gallon IBC totes to facilitate ease of transport to demonstration project sites. BioMAG-EasyPMAC (P3) Product Development and Scale-UPISU and Soylei will develop a P3 formulation and extruder profile that yields a pelletizable/granular BioMAG/SBS extrudate. Prototyping will be conducted in a co-rotating 11-mm twin screw extruder with 5 heating zones and an L/D of up to 40. P3 samples that solubilize under these conditions without agglomerating become candidates for scale-up. Down-selected samples will undergo dose-response studies in asphalt binder testing following AASHTO M320, TP70, and MP19 specifications describing performance grading and MSCR testing. The P3 formulation will be iterated with alternative SBS contents, and ideal SBS content will be determined considering performance, economics, and LCA/EPD aspects.P1 Field Demonstration and AnalysisThe NCAT project team has extensive experience with CR mixtures, including recycling agents to "activate" the RAP binder. The project team will address unknowns in fundamental areas components by leaning on experience, using standard mix design methodologies and thresholds, such as those laid out in AASHTO PP 86, Standard Practice Tracking for Emulsified Asphalt Content of Cold Recycled Mixture Designs, while making appropriate adjustments to the mix design methodology and documenting such adjustments to account for the binder-activating nature of P1.P2 Field Demonstration and AnalysisFor field evaluation, P2 will be applied over the surface of the NCAT Test Tack after the test section experiences around 20 million equivalent single axle loads of traffic with minimum rutting and cracking distresses. Field cores will be obtained from the beginning or the end of each section for the laboratory rheological evaluation of asphalt binders extracted and recovered from the control and treated sections. Additionally, an automated pavement condition survey vehicle will evaluate the control and treated sections for rutting, cracking, smoothness, and surface texture every week.P3 Field Demonstration and AnalysisThe new pilot experiment will be designed to evaluate a modified Stone Matrix Asphalt (SMA) mixture with higher RAP content using P3 in the surface layer of the full-scale test section that has been paved with the P1 CR mixture in the base layer. The field performance of the SMA surface mixture using P3 will be compared with that of the surface layer in the control section sponsored by the Virginia Department of Transportation. The test section will be instrumented and monitored weekly for its rutting, cracking, surface texture, and friction in the field performance.Data will be collected during the production and construction of the pilot experiment for developing EPD and LCA later in this project, and samples of asphalt binder and plant mix will be taken for laboratory testing to assist the field performance evaluation.
Target Audience
During the reporting period, SoyLei targeted a diverse audience with its efforts to demonstrate the use of its products in over 15 miles of roads. The primary audiences reached include: Owner Agencies: These are entities responsible for owning and maintaining road infrastructures. SoyLei's demonstrations are particularly relevant to them as they directly benefit from improved road materials. Department of Transportations (DoTs) across the United States: State and federal DoTs are key stakeholders in road construction and maintenance. By showcasing their products to different DoTs, SoyLei aims to influence the standards and materials used in road construction nationwide. Asphalt Paving Contractors: As the end-users of SoyLei's products, asphalt contractors are a critical audience. Demonstrations to these groups serve to showcase the practicality, efficiency, and benefits of using SoyLei's biobased products in real-world road paving scenarios. Overall, SoyLei's efforts are directed towards stakeholders who have a direct or indirect influence on road construction and maintenance, emphasizing the practical applications and benefits of their products in real-world scenarios.
Changes / Problems
Nothing Reported
Training & Professional Development
SoyLei has consistently emphasized the importance of training and professional development, particularly for our undergraduate students. We've created an environment where these students are not just passive learners but active participants in our projects. By working closely with our experienced researchers and engineers, they gain invaluable hands-on experience that goes beyond the theoretical knowledge obtained in classrooms. This real-world exposure allows them to apply their academic learning in practical settings, enhancing their understanding and skills. Moreover, our approach includes mentorship and guidance from our senior team members. This mentorship is not limited to technical skills; it also encompasses the development of soft skills such as teamwork, communication, and problem-solving, which are crucial in any professional setting. Through regular workshops, seminars, and team collaboration, students are encouraged to ask questions, challenge ideas, and propose solutions, fostering a culture of continuous learning and curiosity. Furthermore, by participating in our projects, students have the opportunity to contribute to meaningful research and engineering challenges. This not only boosts their confidence but also adds significant value to their resumes, aiding in their professional growth and future career prospects. In essence, SoyLei's commitment to incorporating undergraduate students into our projects serves as a catalyst for their professional development, preparing them for successful careers in their respective fields." This response underscores the hands-on experience, mentorship, skill development, and career preparation that SoyLei offers to undergraduate students, aligning with the company's commitment to nurturing future professionals.
Dissemination Streams
The project has utilized a multifaceted approach. Firstly, the demonstration project at the Illinois Farm Progress Show garnered considerable attention from various media outlets, including TV, newspapers, and radio. This exposure was instrumental in showcasing the biobased products to a broader audience. Additionally, the collaboration with the United Soybean Board has been a significant avenue for presenting these products to their network of farmers. This partnership is particularly noteworthy as it emphasizes using U.S.-grown products in the technology, highlighting national agricultural innovation. Furthermore, the presentation of products at various expos across the country has played a crucial role in raising awareness about biobased products. These efforts collectively contribute to a comprehensive dissemination strategy, ensuring that the project reaches a diverse range of communities and stakeholders.
Next Reporting Steps
To accomplish our goals in the next reporting period, our plan involves a continued and focused effort on both testing and demonstrating the biobased products developed by SoyLei. This phase is crucial as it ensures that our products not only meet the high standards we've set but also address the practical needs and expectations of our target market. The demonstration aspect is particularly vital as it allows us to showcase the unique benefits and applications of our biobased products to potential customers and stakeholders. Simultaneously, we will be intensifying our commercialization efforts. This includes strategies aimed at facilitating the mass adoption of our products. We understand that the successful commercialization of these biobased products is not just about creating innovative solutions, but also about creating a market for these solutions. Therefore, we will focus on engaging with key industry players, potential partners, and customers, helping them understand the value and advantages of adopting our biobased products. This dual approach - refining and showcasing our product while also forging strong commercial pathways - is designed to ensure that by the end of the next reporting period, we will have made significant strides towards the widespread acceptance and use of our biobased products. This aligns perfectly with SoyLei's overarching goal of pioneering a sustainable future through innovative, environmentally friendly solutions.