Particle science research makes grain facilities safer

WEST LAFAYETTE, Ind. — A professor at Purdue University is using particle science to improve grain facility safety.

Kingsly Ambrose, professor of agricultural and biological engineering, is researching grain dust explosion prevention, improved fertilizers and grain damage modeling.

The projects are funded by U.S. Department of Agriculture, CNH Industrial and Bayer.

“Particle science is helping to develop new controlled- and slow-release fertilizers that reduce the use of chemical coatings,” Ambrose said.

“Through better characterization and by structural modifications, we are developing innovative solutions that optimize nutrient delivery in fertilizers, prevent dust explosions, minimize grain damage during harvesting and handling, and improve seed germination.”

Grain handling and processing facilities in the United States have experienced a 10-year average of 8.4 incidents annually, he said.

Ambrose and his associates have patented several processes, including one that measures the amount of light passing through a dust cloud to quantify airborne dust in a grain facility.

No previous method enabled grain operators to quickly, easily and continuously monitor dust accumulation in their facilities, according to a press release from Purdue.

Ambrose also patented an algorithm that uses artificial intelligence to automatically calibrate for the type and amount of dust being measured.

“Depending on the grains, the amount of dust will vary,” he said. “Corn generates more dust than wheat, for example. Properties will also differ, so you want separate calibration for each type of dust.”

Studying Grain Damage

Between 5% and 10% of all grains become damaged during combine harvesting or handling and storage.

“Damages could be both internal and external,” Ambrose said. “We lose quality. We lose storability. The value goes down.”

Ambrose blends model development with laboratory testing to identify where most grain damage occurs.

His particle science approach reveals what forces act on the grains as they run through a threshing cylinder or a combine harvester.

Companies can then apply his findings to improve their systems.

“The integration of particle modeling and design allows us to support modern agricultural practices with greater precision,” the professor said.

Urea Findings

Ambrose and his colleagues have also improved the efficiency of urea with a patented process of layer-wise agglomeration of urea granulates.

Agglomeration is a process where urea granules are combined or compacted in layers to form larger clusters. This process improves the granules’ size, shape or handling properties.

“If you apply urea and there is rain, even if there’s high moisture, it dissolves immediately, so the plants may not have enough fertilizer during their growth period,” Ambrose said.

“Our approach here is to make the urea dissolve slowly, without using any additional chemicals to make them release nutrients slowly,” he said.

Ambrose modified the structural components of the urea and mixed it with environmentally friendly ingredients.

“We are also using other methods to control granule density and structural characteristics so that the fertilizer doesn’t dissolve quickly,” he said. “If we can reduce the leaching of urea from the soil, we can help prevent both land and water pollution.”

He hopes that a recent grant from USDA’s Agriculture and Food Research Initiative will lead to further improvement in developing innovative granular urea fertilizers.