Research Programs and Projects at this Location : USDA ARS

ARS Home » Midwest Area » Peoria, Illinois » National Center for Agricultural Utilization Research » Plant Polymer Research » Research » Research Project #428743

Research Project: Renewable Biobased Particles

Location: Plant Polymer Research

2020 Annual Report

Objectives
The goal of this research project is to use a wide range of technological approaches in the utilization of agricultural byproducts and feedstocks to improve functionalities of protein/carbohydrate particles for elastomer, coating, agricultural, medical, and cosmetic applications. Over the next 5 years, we will focus on the following objectives: Objective 1: Enable the commercial production of new products based on functionalized particles for applications in elastomeric composites and latex coatings. Objective 2: Enable new commercial processes to produce marketable biochar particles for rubber composite filler applications. Objective 3: Enable the commercial production of new products based on nano- or micro-particles for controlled-release of chemicals. Objective 4: Enable the commercial production of new products based on biodegradable nanoparticles from starch, and expand their end-use applications. Objective 5: Enable the commercial production of new products based on micro-and nano-sized particles of lignin and cellulose.

Approach
The aim of this research is to develop biobased particle technologies that produce functional particles using renewable agricultural byproducts and feedstocks. The characteristics of the functional particles include size, shape, aggregate structure, and surface functionalities that can be changed for the particles to function as reinforcements in polymer matrices, hydrocolloids for modifying rheological and surface properties, and controlled-release vehicles for delivering chemicals. The outcome of this research will contribute to the utilization of voluminous byproducts generated by the biofuel and food industries, reduction of greenhouse gases responsible for climate change from carbon black production, and sustainability of the global economy. Currently, carbon black is the dominant filler in rubber products. Our previous research on biobased particles has produced natural rubber composites with useful mechanical properties. Further development will be on the regulation of particle connectivity and interface adhesion. Our masterbatch process will be extended to the rheology and films of latex coatings. Carbonized biomaterials as feedstock will also be developed as rubber filler with emphasis on the methods of biochar production to address performance, quality, and supply issues. We have produced nanoparticles of amylose complexes with steam jet cooking technology and will improve particle functionality for composite, coating, and medical applications. We will also develop nano-size cellulose/lignin for composite and cosmetic applications. For controlled-release applications using biobased particles, the functional particles to deliver chemicals, specifically pesticides, will be developed to solve wash-away issues and reduce pesticide consumption. The resulting technologies will be transferred to users who use these products.

Progress Report
This is the final report for this project which terminated in May 2020. See the report for the replacement project, 5010-41000-187-00D, "Agricultural-Feedstock Derived Biobased Products" for additional information. Over the life of this project from FY2015 to FY2020, we have accomplished all the objectives in the plan, including rubber composites, latex coatings, controlled-release particles for chemical delivery, and starch/cellulose/lignin particles for industrial applications. Our contribution to ARS research includes 62 peer-reviewed scientific publications, 18 material transfer agreements and three patents. For the rubber composites and latex coating objective, various polymer composites reinforced with soy based particles and latex coating with soy based thickener were developed, and the results are documented in ten publications. For the biochar objective, various rubbers reinforced with various types of biochar produced by different methods were developed and documented in 5 publications and one material transfer agreement. For the controlled-release objective, protein and biodegradable polymer were developed to encapsulate natural pesticides and are documented in one patent application, 13 material transfer agreements, and two publications. For the starch nanoparticle objective, starch-fatty amine and starch-polymer complex were developed for paper coating, biodegradable film, and antimicrobial applications, and the results are documented in 7 publications, 5 material transfer agreements, one invention disclosure, and one patent application. For the micro-/nano-sized cellulose and lignin objective, the production of micro- and nano-cellulose from agricultural waste were developed and the results are documented in 6 publications, one CRADA agreement, and one patent application. For Fiscal Year 2020, we have met most of our milestones. Our contribution to ARS research includes 13 peer-reviewed scientific publications and one patent application. For rubber composites development, soy based particles were developed into effective reinforcement fillers for rubber applications. The combination of soy based particles with traditional silica or carbon black filler was developed to improve mechanical properties and rolling resistance of tires. For latex paint development, the demand for interior architectural paint is 0.5 billion gallons (approximately 8.4 billion dollars) in the United States. To use these paints effectively requires a paint to have a suitable viscosity so that it can be easily applied to a wall to produce a paint film with a suitable thickness and uniformity without hiding and sagging issues. In the current development, the insoluble soy carbohydrate is obtained by extracting soy protein from defatted soy flour at a high and a low temperature. The insoluble soy carbohydrate obtained contains a different amount of soy protein when processed at different temperatures. The soy carbohydrate from the low temperature process was modified and found to yield a higher viscosity than that from the high temperature process. This progress indicates the improvement of performance and reduction of cost in the development of thickener to adjust the viscosity and flowing behavior of latex paint for commercial applications. The goal of biochar development is to make rubber composites for the tire industry that replace carbon black filler (fossil fuel based) with biochar (from renewable biomass) as much as possible without detrimental effects in the final composite. Initial milestones to determine the best feedstock materials were met as it was found that rapidly growing, sustainable species of poplar and paulownia hardwoods yielded biochar that was high in carbon content (>92%), low in ash content (<5%), and available over large geological areas of the United States. By utilizing silica-milling techniques developed by ARS scientists in Peoria, Illinois, sustainable biochars from poplar and paulownia feedstocks were able to replace 30-50% of the carbon black filler in the three major rubber composite matrices common in the tire industry: styrene-butadiene, natural, and polybutadiene rubber, with minimal performance loss in tensile strength and toughness characteristics of the final composite. ARS scientists hosted a research scientist from the Malaysian Cocoa Board from September 13th to November 23rd, under the Borlaug Fellowship program. The scientist, under the mentorship of an ARS scientist, developed the process of producing biochar from cocoa pod waste. The biochar can be used for the slow release of biochar-based fertilizers by infusing conventional fertilizers into the biochar. For controlled release of chemicals, encapsulation of the target materials into a biodegradable polymer, corn protein (zein), has been investigated. Encapsulation is also a useful technique for improved water-miscibility and improved stability against degradation. Although zein has long been utilized to prepare microcapsules, the encapsulation mechanism for the production of microcapsules has not been well understood. ARS scientists in Peoria, Illinois, have investigated this issue and identified the major controlling factors that govern the encapsulation efficiency. As a result, the optimal conditions for this process were identified. It was also found that most chemicals that do not dissolve in water can be encapsulated into zein particles. So far, it is shown that useable chemicals include certain essential oils that can be used as a natural pesticide for pests and functional ingredients from natural sources (for example, polyunsaturated fatty acids such as fish oils, or phytochemicals such as polyphenols, phytosterols, etc.). As a trial to lower the production cost, other types of proteins, such as wheat, soy, and rice proteins, are being examined. The composite plastic bars with micro-sized lignin were prepared. The mechanical properties of these plastic bars were studied. The mechanical properties of the bars prepared with different sizes of lignin particles were compared. The systematical rheological and micro-rheological properties of nano-sized cellulose gels produced from corn stover were characterized. The viscoelastic (material behavior between solid and liquid) properties of the corn stover nanocellulose gels dependence of concentration were investigated. The micro-rheological and micro-heterogeneity properties of the corn stover nanocellulose gels were also conducted. The macro-rheology and micro-rheology of the corn stover nanocellulose gels were compared. The macro-rheology and micro-rheology of the corn stover nanocellulose exhibited concentration-dependent solid-like properties. Higher nanocellulose concentrations resulted in stronger properties. The analysis for different concentrations of the corn stover nanocellulose gels indicated that they were physical gels, meaning the cross-linkers between the molecules exhibited physical interactions. The corn stover nanocellulose gels high-frequency behavior indicated that the corn stover nanocellulose chains were semi-flexible. The properties of the corn stover nanocellulose gels were compared with the properties of some commercial wound healing gels and cosmetic gels, and they were similar. ARS scientists in Peoria, Illinois, developed nano-sized cellulose from agricultural waste and micro-sized lignin; investigated physical, mechanical, and rheological properties of these nanocellulloses and micro-lignins; and identified potential applications for these new bio-materials. Our research contributes to the national economy by creating new applications and potential markets for agricultural materials.

Accomplishments
1. Improved process of producing modified soy carbohydrate as a thickener for latex paint. Flowing properties are important in the application of latex paint, which is required to have a suitable viscosity so that it can be easily applied onto a wall to form a film of suitable thickness and uniformity without hiding and sagging issues. ARS scientists in Peoria, Illinois, have studied the effect of temperature on the composition and characteristics of insoluble soy carbohydrate from soy protein extraction process for the production of modified soy carbohydrate as a thickener to be used in latex paint. This development will increase the value of soy carbohydrate, which is currently a waste byproduct from the production process of soy protein. The added value of soy carbohydrate will contribute to the rural economy.

2. Use of proteins to provide an anti-fogging surface. Anti-fogging agents are chemicals that prevent the condensation of water in the form of small droplets on a surface. Without anti-fogging treatment, condensed water forms fog-like droplets on the surface of glass or plastics and scatters light, causing low visibility. ARS scientists in Peoria, Illinois, have improved on a previously patented ARS invention to produce protein nanoparticles that outperform commercial anti-fogger solutions. These biodegradable nanoparticles are made using proteins (for example from wheat, soybean or milk) with a petroleum-based material. Any surface which may have water fogging or beading on it will benefit. This includes surfaces such as windows on cars, boats, homes, and buildings. In addition, eyewear, such as eyeglasses, medical and swim googles, will also benefit. Depending on the protein used, participants in the wheat or soybean or milk value chain will benefit as well as the end consumer.

3. Improved products using nanocellulose derived from corn stover. Cellulose is the polymer found in plants and is responsible for the plant’s strength. If the cellulose is reduced in size to the ‘nano’ scale (one billionth of a meter) it is called nanocellulose (NC). NC produced from corn stover (that part of the corn plant that is not seeds) was developed by ARS scientists in Peoria, Illinois. NC has been shown to provide value in many end-uses from polymer blends to medical devices, and cosmetics to waste treatment. In all of these applications, the NC must flow (be pumped) from one location to the next. For the full value of corn stover NC to be realized, its flow properties must be understood. By using state of the art techniques, the flow properties of NC suspensions were determined allowing for improved NC based products to be produced. By developing a high value use from what is normally left over on the corn field will benefit corn producers and processors.

U.S. DEPARTMENT OF AGRICULTURE

Plant Polymer Research: Peoria, IL