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How to Bin for Profit – Storing Grain to
Maximize Quality and Blend
Convey’21
Omaha, Nebraska
July 13-14, 2021
Dirk E. Maier, Ph.D., P.E.
Professor, Agricultural & Biosystems Engineering
Post-Harvest Engineer, Iowa Grain Quality Initiative
Director, ISU Feed Mill & Grain Science Complex
dmaier@iastate.edu
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
State-of-the-art grain handling, drying, storage and feed processing
facility to further ISU’s teaching, research, service, extension and
industry outreach mission.
1. To provide an environment of the highest safety standards,
biosecurity, and regulatory compliance
2. To enhance ISU teaching programs related to feed technology,
animal nutrition, and grain operations & quality
3. To provide extension and industry outreach programming related
to feed technology, animal nutrition, and grain operations &
quality training, demonstration and continuing education
4. To support ISU animal nutrition, feed technology, and grain
operations & quality research programs
5. To manufacture diets and feeds for the university's livestock and
poultry teaching and research farms
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Iowa Corn
Education Building
Probe Station
Sukup Grain Center
Truck Scale
Kent Feed Mill
Dryer
Test Stand
Iowa State University Kent Corporation
Feed Mill and Grain Science Complex
Education Vision for Students
• Provide a growing pool of recruitable interns and
knowledgeable employees for Iowa’s (and the region’s) grain,
feed and allied industries
• operations, nutrition, technology, engineering, management
• Provide undergraduate and graduate student teaching and
practical training in feed technology and grain operations
– Multidisciplinary minor in Feed Technology
• Students in Ag Systems Technology, Animal Science, Ag
Business, Ag Studies
– New courses in feed technology and feed safety
• Future courses in feed mill business management, advanced mill
operations and technologies, …
– Hands-on experiences in new pilot facility, feed mill, and hands-on
training center
Feed Technology Minor
(https://catalog.iastate.edu/interdisciplinaryprograms/minor/feedtechnology/)
Course Title Credits
TSM 322 & 322L or
ABE 469
Preservation of Grain Quality & Lab or
Grain Processing and Handling
3
TSM 455 Feed Processing and Technology (new course) 3
TSM 457 Feed Safety, Ingredient Quality & Analytics (new course) 3
AnS 320 Animal Feeds and Feeding 3
AnS 324 Food Processing for Companion Animals 3
Total 15
Feed Technology Minor
Feed Technology Minor
Industry On-site Course Offerings
• Advanced Grain Elevator Operations Management
(AGEOM) Short Course
– Focuses on advanced grain elevator operations mgmt
– Target group: operations managers, location superintendents
– 3 CEUs and Professional Engineers (P.E.) hours
– IGQI-AAI: 1st week in January (2018, 19, 20, 21)
• Jan’21 offering converted to a virtual course focused on Grain
Quality Management (offered February 15-19, 2021)
– Custom offerings:
– in collaboration with other associations (GFAI, GEAPS)
– to support company in-house training of employees (CVA, IAS)
AGEOM On-site Course Offering
First post-Covid in-person AGEOM course in partnership with
Grain & Feed Association of Illinois June 21-25, 2021
Hands-On Training Center
• Hands-on training center for equipment maintenance,
personnel safety, regulatory compliance, and
developing technical competence
– Target group: operations employees of grain elevators
and feed mills, community college/university students
– Model: Cargill Operations Training Center (Iowa Falls, IA),
Asmark Institute (Bloomington, IL)
– Advisory Team: Bob Marlow, Jeff Showalter, John Lee
– Facility: existing warehouse structure adjacent to ISU
Feed Mill & Grain Science Complex
– Sponsorships/Partnerships: Available/Industry-wide
Quality Grain is Job #1!
Equilibrium Moisture Content (EMC)
EMC is the moisture content at which grain will
equilibrate when exposed to particular drying or
rewetting air conditions
 This relationship is of particular importance for
grain cooling, drying, conditioning and rewetting
Equilibrium Moisture Content (EMC)
• For fan operation
management to cool,
dry, condition or
rewet...
• Given certain
conditions of air
temperature and RH...
What MC will the grain
equilibrate toward?
How to manage
shrink?
Inlet Air
Temperature and
Relative Humidity
Grain
Moisture?
Corn Equilibrium Moisture Content Isotherm
0
10
20
30
40
50
60
70
80
90
100
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Humedad del Grano (%)
Humedad
Relativa
de
Equilibrio
(%)
Ambient air at 50°F (10°C) – Ambient RH is changed stepwise
Grain Moisture Content (%)
Air
Relative
Humidity
(%)
Set AC unit to 50°F
(10°C) and 70% RH.
After sometime corn
will equilibrate at
about 14-15%.
Set AC unit to 50°F
(10°C) and 30% RH.
After sometime corn will
equilibrate at about 10%.
It will not go down further,
even if you wait longer.
Set AC unit to 50°F
(10°C) and 90% RH.
After sometime corn will
equilibrate at about 20%.
It will not go up further,
even if you wait longer.
This line is called isotherm, meaning that for each
temperature there is one curve
Equilibrium Relative Humidity (ERH)
• Given a certain condition of grain
temperature and moisture content, what is
the relative humidity of the interstitial air?
• Recall corn isotherm line...
Grain Moisture Content at 50°F (10°C)
10% 15% 20%
30% RH
70% RH
90% RH
If corn is stored at
10% MC, the RH in
the interstitial air will
be about 30%
If corn is stored at
15% MC, the RH in
the interstitial air will
be about 70%
If corn is stored at
20% MC, the RH in
the interstitial air will
be about 90%
 Grain composition
affects EMC
 The higher the oil
content, the higher
the equilibrium MC
 For the same MC,
the ERH in the
interstitial air is
higher
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
5 7 9 11 13 15 17 19 21 23
Equilibrium
Relative
Humidity
(%)
Equilibrium Grain Moisture Content (%)
Wheat
Soybean
Corn
Sunflower
Rice
Composition Effect on EMC – Different Grain Types
Oil content
Corn
Wheat
Rice
13% MC
65% RH
13% MC
70% RH
< 10% 20-25% 45-50%
Soybean Sunflower
Canola
13% MC
90% RH
Equilibrium moisture content
relationships are grain specific!!!!
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
5 7 9 11 13 15 17 19 21 23
Equilibrium
Relative
Humidity
(%)
Equilibrium Grain Moisture Content (%)
Wheat
Soybean
Corn
Sunflower
Rice
Sunflower Soy
Oilseeds Cereals
Safe storage MC for different grains and oilseeds
Unsafe
storage
Safe
storage
67%
RH
Safe storage
conditions for
cereals is about 13-
15% MC
Corn
Wheat
Rice
Safe storage
conditions for
oilseeds is lower
(depending on oil
content)
Calculate EMC, ERH, and Safe Storage Moisture…
NEW Grain Aeration and Storage App
NEW Grain Aeration & Storage App
NEW Grain Aeration & Storage App
S.L.A.M.
Quality Grain Management
• Sanitation
• Loading
• Aeration
• Monitoring
S.L.A.M. Step 1: Sanitation
• Handling equipment
• Transportation vehicles
• Storage structures (inside and outside)
• Pest prevention (“Sanitation is pest control!”)
S.L.A.M. Step 2: Loading
• Screening/Pre-cleaning
• Coring (un-peaking; single vs. multiple withdrawals)
• Leveling (mechanical or gravity spreading)
• Sealing (fans, leaks, cracks)
Core of fines
• Foreign
Material (FM)
• Broken grain
• Weed seeds
Peaked Grain – Effect on Airflow and
Grain Temperature
Coring
1/3-1/2 bin dia.
Core
Grain bulk
One time coring
• Eliminate grain
peak (un-peak)
• Remove core
of BCFM
• Improve airflow
through center
• Better monitor
grain surface
S.L.A.M. Step 3: Aeration
Air Conditions, EMC and Grain Aeration
Selecting proper
ambient air conditions
during fan operation
hours is critical for
avoiding overdrying
during long term
storage
What happens to grain MC when aeration fan
is turned on?
Grain will
slowly
equilibrate
with the
ambient air
condition
based on the
EMC
relationship
Corn at
14%
MC
68°F and
60% RH
68°F and
80% RH
68°F and
70% RH
Ambient air condition
After enough fan run
hours grain equilibrates
to average air condition
12% MC
14% MC
16% MC
Equilibrium
Air
RH%
Reed Book Fig 18, p165
Wheat and Air Equilibrium at 12%
Moisture Content
50 55 60 65 70 75 80 85 90 95 100
Air Temperature (F)
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Absolute
Humidity
(lb
water/lb
air)
100 %Relative Humidity
50 %Relative Humidity
Wheat 12 % m.c.
Reed Book Fig 19, p166
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
50 55 60 65 70 75 80 85 90 95 100
Absolute
Humidity
(lb
water/lb
air)
Air Temperature (F)
100 % Relative Humidity
50 % Relative Humidity
Wheat 12 % m.c.
Grain Temp
= 95 ºF
Air temp = 77 ºF
Air R. H. = 80 %
Air temp = 75°F
Air R.H. = 80%
Wheat with 12% m.c. at 95ºF aerated
with air at 75ºF and 80% R.H.
==> What is the Twb of this air?
Reed Book Fig 20, p167
Final temperature of wheat at 12% m.c.
aerated with air at 75ºF Tdb, 80% R.H. and
70ºF Twb
50 55 60 65 70 75 80 85 90 95 100
Air Temperature (F)
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Absolute
Humidity
(lb
water/lb
air)
100 %Relative Humidity
50 %Relative Humidity
Wheat 12 % m.c.
Initial
Temp
Cooling Air
= 70°F Twb
Final Grain
Temperature
82°F
Note: Grain Moisture Trend = 16.9%
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
50 55 60 65 70 75 80 85 90 95 100
Absolute
Humidity
(lb
water/lb
air)
Air Temperature (F)
100 % Relative Humidity
50 % Relative Humidity
Corn 16 % m.c.
Wet-Bulb Lines
Corn with 16% m.c. at 75ºF aerated
with air at 60ºF and 50% R.H.
Air temp = 60°F
Air R.H. = 50%
Final temperature of corn at 16% m.c.
aerated with air at 60ºF and 50% R.H. and
50ºF Twb
50 55 60 65 70 75 80 85 90 95 100
Air Temperature (F)
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
Absolute
Humidity
(lb
water/lb
air)
100 %Relative Humidity
50 %Relative Humidity
Corn 16 % m.c.
Wet-Bulb Lines
Corn at 75 ºF
Cooling Air = 50°F Twb
Final Grain
Temperature
54°F
Air temp = 60°F
Air R.H. = 50%
Note: Grain Moisture Trend = 11.9%
NEW Grain Aeration & Storage App
NEW Grain Aeration & Storage App
Aeration Decision Matrix
Grain
Moisture
Content
(%)
Air-Grain
Temp
Difference
(°F)
Air much
cooler
than Grain
Cooling
decision
criteria
-5°F
Air much
warmer
than Grain
• Phase 1: Fall Cool Down
• Lower grain temperatures stepwise
• October 40-45°F
• November 35-40°F
• December 28-35°F
• Phase 2: Winter Maintenance
• Maintain temperatures with intermittent aeration
• January, February 28-35°F
• Phase 3: Spring Holding
• Keep cold grain cold
• Seal fans
• Ventilate headspace intermittently
S.L.A.M. Step 3: Aeration
Rule of Thumb for Aeration Shrink
Total Bushel shrink =
Bu aerated x degree temp drop x 0.022 x 1.2%
Example:
• 50,000 bushel bin corn at 15.5% mc and 70°F
• Cool to 50°F @ 75% = 264 bu of shrink during Oct cycle (15.2% mc)
• Cool to 40°F @ 69% = 131 bu of shrink during Nov cycle (15.1% mc)
• Cool to 30°F @ 64% = 131 bu of shrink during Dec cycle (15.0% mc)
• Total Shrink = 526 bushels of aeration shrink
• Expected final moisture content = 15.0-15.2%
Moisture Loss due to Excessive Aeration of Corn
15.5% MC
15.5% MC
15.5% MC
15.5% MC
14.0% MC
12.5% MC
10.0% MC
lb of water
evaporated =
loss of money
15.5% MC
Instead of this Mostly end up like this
Value of Corn Lost due to Over-Aerating
15.5% MC
14.0% MC
12.5% MC
10.0% MC
Bin Size
lb of water
evaporated
Bushel of
water
Loss of
Money
D60 H45
(103,000 bu)
165,744 2,960 $11,839
D84 H75
(334,000 bu)
537,216 9,593 $38,373
D105 H90
(626,000 bu)
1,007,280 17,987 $71,949
Calculated based on $4/bu of corn
lb of water
evaporated =
loss of money
EMC Controlled Aeration of Corn
15.5% MC
15.5% MC
15.5% MC
15.5% MC
15.2% MC
15.0% MC
14.8% MC
15.5% MC
lb of water
evaporated =
loss of money
Instead of this
(Ideal)
Achieve this (Practical)
Shrink Loss Reduction for Corn Aeration
Bin Size
Uncontrolled Aeration Controlled Aeration
Shrink Loss/year Shrink Loss/year
60 x 45 $11,839 $1,820
84 x 75 $38,373 $5,900
105 x 90 $71,949 $11,062
Uncontrolled Aeration
Bottom Layer: 10%
Top Layer: 15.5%
Controlled Aeration
Bottom Layer: 14.9%
Top Layer: 15.5%
Savings of 6X
page 54
Aeration at any initial Corn temperature…
Initial MC
(%)
50°F / 60% 50°F / 80% 40°F / 60% 40°F / 80%
13.0% 50.4°F / 13.3% 54.0°F / 16.5% 41.0°F / 13.8% 43.9°F / 17.0%
13.5% 49.8°F / 13.3% 53.2°F / 16.5% 40.5°F / 13.8% 43.2°F / 17.0%
14.0% 49.1°F / 13.3% 52.5°F / 16.5% 39.9°F / 13.8% 42.6°F / 17.0%
14.5% 48.6°F / 13.3% 52.0°F / 16.5% 39.4°F / 13.8% 42.0°F / 17.0%
15.0% 48.0°F / 13.3% 51.4°F / 16.5% 38.8°F / 13.8% 41.5°F / 17.0%
15.5% 47.5° / 13.3% 50.9°F / 16.5% 38.5°F / 13.8% 41.2°F / 17.0%
12.7% MC
12.5% MC
12.3% MC
13.0% MC
11.5% MC
10.0% MC
8.0% MC
13.0% MC
Moisture Loss due to Excessive Aeration of Soybean
lb of water
evaporated =
loss of money
Instead of this Mostly end up like this
13.0% MC
11.5% MC
10.0% MC
8.0% MC
Bin Size
lb of water
evaporated
Bushel of
water
Loss of
Money
60 x 45 164,221 2,737 $21,896
84 x 75 532,278 8,871 $70,970
105 x 90 998,022 16,634 $133,070
Value of Soybeans Lost due to Over-Aerating
Calculated based on $8/bu of soybeans
lb of water
evaporated =
loss of money
EMC Controlled Aeration of Soybeans
13.0% MC
13.0% MC
13.0% MC
13.0% MC
12.8% MC
12.6% MC
12.3% MC
13.0% MC
lb of water
evaporated =
loss of money
Instead of this
(Ideal)
Achieve this (Practical)
Bin Size
Uncontrolled
Aeration
Controlled
Aeration
Shrink Loss/year Shrink Loss/year
60 x 45 $21,896 $3,536
84 x 75 $70,970 $11,462
105 x 90 $133,070 $21,492
Uncontrolled Aeration
Bottom Layer: 8.0%
Top Layer: 13.0%
Controlled Aeration
Bottom Layer: 12.3%
Top Layer: 13.0%
Shrink Loss Reduction for Soybeans Aeration
Savings of 6X
Aeration at any initial Soybean temperature…
Initial MC
(%)
50°F / 60% 50°F / 80% 40°F / 60% 40°F / 80%
11.0% 50.2°F / 11.2% 54.9°F / 15.6% 40.5°F / 11.5% 43.3°F / 15.9%
11.5% 49.8°F / 11.2% 53.4°F / 15.6% 40.1°F / 11.5% 43.0°F / 15.9%
12.0% 49.3°F / 11.2% 52.9°F / 15.6% 39.6°F / 11.5% 42.4°F / 15.9%
12.5% 48.7°F / 11.2% 52.3°F / 15.6% 39.2°F / 11.5% 42.1°F / 15.9%
13.0% 48.4°F / 11.2% 52.0°F / 15.6% 38.8°F / 11.5% 41.7°F / 15.9%
13.5% 48.0°F / 11.2% 51.4°F / 15.6% 38.7°F / 11.5% 41.4°F / 15.9%
14.0% 47.7°F / 11.2% 51.1°F / 15.6% 38.3°F / 11.5% 41.0°F / 15.9%
14.5% 47.3°F / 11.2% 50.7°F / 15.6% 37.9°F / 11.5% 40.8°F / 15.9%
page 59
Predicting suitable aeration periods
based on weather forecast…
• NEW Grain Aeration and Storage
App loads local 6-day weather
forecast
– Indicates average and minimum
ambient temperature
• Allows for selection of % of coolest
hours available for next 6 days
– 50% = selects the 50% coolest
hours of each day, or all hours
below the daily average
temperature, and provides the
recommended thermostat set-point
temperature to achieve that target
– 100% = maximizes fan run hours
but results in a higher thermostat
set-point temperature
NEW Grain Aeration & Storage App
Spring Aeration
Should cooled grain be
warmed up in the spring?
Idealized Aeration Schedule
?
Winter & Summer Holding Period
Aeration cooling potential of corn & soybeans
Des Moines – Iowa (2015-19; 5-year average)
Average Temperature = 52.2 +/- 19.0°F
Average Relative Humidity = 70.2 +/- 6.0%
Des Moines – Iowa (2015-19; 5-year average)
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Aeration cooling potential of corn & soybeans
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
Des Moines – Iowa (2015-19; 5-year average)
Air EMC trend for corn & soybeans
15%
13%
Average Temperature = 52.2 +/- 19.0°F EMC = 14.7% Corn
Average Relative Humidity = 70.2 +/- 6.0% EMC = 13.2% Soybeans
47 F
Des Moines – Iowa (2015 - 2019)
Cooling potential of corn
in November
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
Des Moines – Iowa (2015 - 2019)
Cooling potential of corn
in February
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
Des Moines – Iowa (2015 - 2019)
Cooling potential of corn
in April
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
Des Moines – Iowa (2015 - 2019)
Cooling potential of corn
in July
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
135,000 bu Bin of Corn during
Summer Storage in Indiana –
Non-aerated on 7/28/89
8
10
10
10
10
10
10
12
1
2
12
14
14
14
14
14
14
14
16
16 16
16 16
18
18
18
18
20
20
20
20
22
22
22
2
2
22
24
24
24
24 24
2
6
26
26
26
26 26
28
28
28
28
28
28
3
0
30
30
30
34
r (m)
z
(m)
0 5 10
0
2
4
6
8
10
12
14
16
18
T(C)
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
7/28/1988 24:00
7/28/1989 24:00
13.8
14
1
4
14
14
r (m)
z
(m)
0 5 10
0
2
4
6
8
10
12
14
16
18
MC(%w.b.)
14.5
14.4
14.3
14.2
14.1
14
13.9
13.8
13.7
13.6
13.5
7/28/1988 24:00
7/28/1989 24:00
97°F
86°F
68°F
50°F
41°F
32°F
Spring Aeration
Should cooled grain be
warmed up in the spring?
NO!
Open Fan
Sealed Fan
Sealed Fan
Headspace Ventilation
Headspace Ventilation
Headspace Ventilation
What about Aerated Grain Piles?
Des Moines – Iowa (2015-19; 5-year average)
Winter < 40°F
Fall & spring = 50-60°F
Summer = 60-77°F
Continuous Aeration of a Grain Pile
Winter R.H. = 70-75%
Fall & spring = 60-73%
Summer = 65-73%
Average Temperature = 52.2 +/- 19.0°F  Oct-Mar = 36.2°F
Average Relative Humidity = 70.2 +/- 6.0%  Oct-Mar = 71.3%
Des Moines – Iowa (2015-19; 5-year average)
Continuous Aeration of a Grain Pile
15%
13%
Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F
Oct-Mar = 71.3% EMC = 13.9% Soybeans
47 F
Des Moines – USA (2016)
Continuous Aeration of a Grain Pile
41 50 59 63 68 77 81 86
~5 months when ambient
temperatures are below 40°F
for at least 300 h of aeration
time each month (50% of time)
Suitable airflow: 0.05-0.1 cfm/bu
Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F
Oct-Mar = 71.3% EMC = 13.9% Soybeans
Des Moines – USA (2016)
Continuous Aeration of a Grain Pile
41 50 59 63 68 77 81 86
~6.5 months when ambient
temperatures are below 50°F
for at least 300 h of aeration
time each month (of time)
Suitable airflow: 0.05-0.1 cfm/bu
Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F
Oct-Mar = 71.3% EMC = 13.9% Soybeans
Des Moines – USA (2016)
Continuous Aeration of a Grain Pile
41 50 59 63 68 77 81 86
3 m x 30 d x 24 h
= 2,160 hours
Apr-Sep = 68.3°F EMC = 13.7% Maize Wet bulb = 61.7°F
Apr-Sep = 69.0% EMC = 12.5% Soybeans
Effect of continuous pile aeration on corn
Effect of continuous pile aeration on soybean
Summary – Managing Aeration Shrink Loss
1. Aeration cooling of grain follows the wet bulb
temperature
 line on the psychrometric chart
2. For given air properties, the dry bulb temperature
the grain will cool to and the moisture content the
grain will equilibrate towards can be calculated
 based on equilibrium moisture content (EMC) and
equilibrium relative numidity (ERH) relationship
3. Shrink loss due to aeration cooling can be calculated
based on evaporative cooling effect
4. Shrink loss costs includes moisture loss and electric
fan energy due to excessive operation
S.L.A.M. Step 4: Monitoring
• Temperature
• Moisture
• CO2
• Molds (cause spoilage and hot spots)
• Insects
• Mold feeders are an early warning
• Population growth leads to “hot spots”
• Late summer pest control (fumigation)
• Rodents
As a rule of thumb, one cable monitors a radius of 9 feet.
Temperature Cable Placement Calculations
• Sensors are typically 7 ft apart along a cable
• Assume sphere with a radius of 3.5 ft around
each sensor without overlap between sensor
volumes, the three cable configurations would
represent…
Temperature Cable Placement Recommendations
1.5% 4.6% 10.8%
92
Results: 48x60 ft bin
3000 TCs 40oF
15 TCs 36oF
30 TCs 38oF
77
59
41
23
5
-13
93
Results: 48x60 ft bin
3000 TCs 40oF
15 TCs 36oF
30 TCs 38oF
3000 TCs 27oF
15 TCs 24oF
30 TCs 18oF
77
59
41
23
5
-13
“No Cables” T/RH/CO2 Monitoring & Fan Control
https://app.amber.ag/dashboard
95
Installation of the Amber Ag ACE Air Tools
How does “no cables” sensing technology work?
• Measures T, RH and CO2 of air in
headspace above and/or plenum
below the stored grain mass
• Calculates EMC of the headspace or
plenum air when fan is off or inlet air
and exhaust air when fan is on
• All sensors and fan controllers
communicate as a stand alone cellular
connection to the Amber cloud
• Advantages:
• Easy installation
• Easy serviceability
• Less expensive (11 cents/bu)
• No cables in grain mass
• No structural roof issues
• Automatic fan control
• No interference
• Disadvantages:
• No in-grain temperature and
moisture sensing
Summary: More Advantages than Disadvantages
Amber CO2
monitor
“No cables” T/RH/CO2 Monitoring & Fan Control
“No cables” T/RH/CO2 Monitoring & Fan Control
“No cables” T/RH/CO2 Monitoring & Fan Control
Handheld carbon dioxide (CO2) sensors
page 101
• Advantages:
• Faster than T/RH sensors
• No structural issues
• Versatile use (bin, outdoor pile)
• Disadvantages:
• Hand-held
• Cost: Telaire 7001: $459
https://www.microdaq.com/telaire-7001-carbon-dioxide-co2-monitor.php
• Up to 600 ppm: stable grain at safe storage MC
• 600-1500 ppm: on-set of mold growth
• high grain storage temperatures
• moisture condensation on grain surface, or
• moisture infiltration into structure
• 1500 to 4000 ppm: active grain spoilage
• high biological activity in portions of grain mass
• severe mold development, or
• severe stored-product insect infestation
Interpreting CO2 concentrations
1. Stored grain conditions can be monitored with
temperature, moisture and CO2 sensors
• Beware of number of cables and their placement
2. Regular monitoring of stored grain conditions
allows for early spoilage detection and proactive
operations management action
3. Early detection of spoilage using CO2 monitoring
saves time and money
• New “no cables” technology provides plug-n-play
options and automated fan control
Summary – Stored Grain Conditions
Monitoring
Quality Grain is Job #1!
S.L.A.M.
Best Stored Grain Management Practices
• Prepare/clean your storage bins for new crop harvest
• Dry grain then store at safe storage moisture content
• Core & “un-peak” grain mass after loading bins
• Aerate to cool grain (not shrink it) then seal fans
• Manage headspace conditions with intermittent
ventilation
• Monitor grain regularly for CO2, surface condensation,
temperature, insect activity, mold development
Contact Information
Dr. Dirk E. Maier, Ph.D., P.E.
Professor of Grain & Feed Operations & Processing
Agricultural & Biosystems Engineering Department
Post-Harvest Engineer
Iowa Grain Quality Initiative
3325 Elings Hall
Iowa State University
Ames, Iowa, U.S.A.
dmaier@iastate.edu

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4. How to Bin for Profit - Storing Grain to Maximize Quality and Blend

  • 1. How to Bin for Profit – Storing Grain to Maximize Quality and Blend Convey’21 Omaha, Nebraska July 13-14, 2021 Dirk E. Maier, Ph.D., P.E. Professor, Agricultural & Biosystems Engineering Post-Harvest Engineer, Iowa Grain Quality Initiative Director, ISU Feed Mill & Grain Science Complex dmaier@iastate.edu
  • 2. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 3. State-of-the-art grain handling, drying, storage and feed processing facility to further ISU’s teaching, research, service, extension and industry outreach mission. 1. To provide an environment of the highest safety standards, biosecurity, and regulatory compliance 2. To enhance ISU teaching programs related to feed technology, animal nutrition, and grain operations & quality 3. To provide extension and industry outreach programming related to feed technology, animal nutrition, and grain operations & quality training, demonstration and continuing education 4. To support ISU animal nutrition, feed technology, and grain operations & quality research programs 5. To manufacture diets and feeds for the university's livestock and poultry teaching and research farms Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 4. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 5. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 6. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 7. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 8. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 9. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 10. Iowa State University Kent Corporation Feed Mill and Grain Science Complex Iowa Corn Education Building Probe Station Sukup Grain Center Truck Scale Kent Feed Mill Dryer Test Stand
  • 11. Iowa State University Kent Corporation Feed Mill and Grain Science Complex
  • 12. Education Vision for Students • Provide a growing pool of recruitable interns and knowledgeable employees for Iowa’s (and the region’s) grain, feed and allied industries • operations, nutrition, technology, engineering, management • Provide undergraduate and graduate student teaching and practical training in feed technology and grain operations – Multidisciplinary minor in Feed Technology • Students in Ag Systems Technology, Animal Science, Ag Business, Ag Studies – New courses in feed technology and feed safety • Future courses in feed mill business management, advanced mill operations and technologies, … – Hands-on experiences in new pilot facility, feed mill, and hands-on training center
  • 13. Feed Technology Minor (https://catalog.iastate.edu/interdisciplinaryprograms/minor/feedtechnology/) Course Title Credits TSM 322 & 322L or ABE 469 Preservation of Grain Quality & Lab or Grain Processing and Handling 3 TSM 455 Feed Processing and Technology (new course) 3 TSM 457 Feed Safety, Ingredient Quality & Analytics (new course) 3 AnS 320 Animal Feeds and Feeding 3 AnS 324 Food Processing for Companion Animals 3 Total 15
  • 16. Industry On-site Course Offerings • Advanced Grain Elevator Operations Management (AGEOM) Short Course – Focuses on advanced grain elevator operations mgmt – Target group: operations managers, location superintendents – 3 CEUs and Professional Engineers (P.E.) hours – IGQI-AAI: 1st week in January (2018, 19, 20, 21) • Jan’21 offering converted to a virtual course focused on Grain Quality Management (offered February 15-19, 2021) – Custom offerings: – in collaboration with other associations (GFAI, GEAPS) – to support company in-house training of employees (CVA, IAS)
  • 17. AGEOM On-site Course Offering First post-Covid in-person AGEOM course in partnership with Grain & Feed Association of Illinois June 21-25, 2021
  • 18. Hands-On Training Center • Hands-on training center for equipment maintenance, personnel safety, regulatory compliance, and developing technical competence – Target group: operations employees of grain elevators and feed mills, community college/university students – Model: Cargill Operations Training Center (Iowa Falls, IA), Asmark Institute (Bloomington, IL) – Advisory Team: Bob Marlow, Jeff Showalter, John Lee – Facility: existing warehouse structure adjacent to ISU Feed Mill & Grain Science Complex – Sponsorships/Partnerships: Available/Industry-wide
  • 19. Quality Grain is Job #1!
  • 20. Equilibrium Moisture Content (EMC) EMC is the moisture content at which grain will equilibrate when exposed to particular drying or rewetting air conditions  This relationship is of particular importance for grain cooling, drying, conditioning and rewetting
  • 21. Equilibrium Moisture Content (EMC) • For fan operation management to cool, dry, condition or rewet... • Given certain conditions of air temperature and RH... What MC will the grain equilibrate toward? How to manage shrink? Inlet Air Temperature and Relative Humidity Grain Moisture?
  • 22. Corn Equilibrium Moisture Content Isotherm 0 10 20 30 40 50 60 70 80 90 100 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Humedad del Grano (%) Humedad Relativa de Equilibrio (%) Ambient air at 50°F (10°C) – Ambient RH is changed stepwise Grain Moisture Content (%) Air Relative Humidity (%) Set AC unit to 50°F (10°C) and 70% RH. After sometime corn will equilibrate at about 14-15%. Set AC unit to 50°F (10°C) and 30% RH. After sometime corn will equilibrate at about 10%. It will not go down further, even if you wait longer. Set AC unit to 50°F (10°C) and 90% RH. After sometime corn will equilibrate at about 20%. It will not go up further, even if you wait longer. This line is called isotherm, meaning that for each temperature there is one curve
  • 23. Equilibrium Relative Humidity (ERH) • Given a certain condition of grain temperature and moisture content, what is the relative humidity of the interstitial air? • Recall corn isotherm line... Grain Moisture Content at 50°F (10°C) 10% 15% 20% 30% RH 70% RH 90% RH If corn is stored at 10% MC, the RH in the interstitial air will be about 30% If corn is stored at 15% MC, the RH in the interstitial air will be about 70% If corn is stored at 20% MC, the RH in the interstitial air will be about 90%
  • 24.  Grain composition affects EMC  The higher the oil content, the higher the equilibrium MC  For the same MC, the ERH in the interstitial air is higher 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 5 7 9 11 13 15 17 19 21 23 Equilibrium Relative Humidity (%) Equilibrium Grain Moisture Content (%) Wheat Soybean Corn Sunflower Rice Composition Effect on EMC – Different Grain Types Oil content Corn Wheat Rice 13% MC 65% RH 13% MC 70% RH < 10% 20-25% 45-50% Soybean Sunflower Canola 13% MC 90% RH Equilibrium moisture content relationships are grain specific!!!!
  • 25.
  • 26. 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 5 7 9 11 13 15 17 19 21 23 Equilibrium Relative Humidity (%) Equilibrium Grain Moisture Content (%) Wheat Soybean Corn Sunflower Rice Sunflower Soy Oilseeds Cereals Safe storage MC for different grains and oilseeds Unsafe storage Safe storage 67% RH Safe storage conditions for cereals is about 13- 15% MC Corn Wheat Rice Safe storage conditions for oilseeds is lower (depending on oil content)
  • 27. Calculate EMC, ERH, and Safe Storage Moisture… NEW Grain Aeration and Storage App
  • 28. NEW Grain Aeration & Storage App
  • 29. NEW Grain Aeration & Storage App
  • 30. S.L.A.M. Quality Grain Management • Sanitation • Loading • Aeration • Monitoring
  • 31. S.L.A.M. Step 1: Sanitation • Handling equipment • Transportation vehicles • Storage structures (inside and outside) • Pest prevention (“Sanitation is pest control!”) S.L.A.M. Step 2: Loading • Screening/Pre-cleaning • Coring (un-peaking; single vs. multiple withdrawals) • Leveling (mechanical or gravity spreading) • Sealing (fans, leaks, cracks)
  • 32. Core of fines • Foreign Material (FM) • Broken grain • Weed seeds
  • 33. Peaked Grain – Effect on Airflow and Grain Temperature
  • 34. Coring 1/3-1/2 bin dia. Core Grain bulk One time coring • Eliminate grain peak (un-peak) • Remove core of BCFM • Improve airflow through center • Better monitor grain surface
  • 35. S.L.A.M. Step 3: Aeration
  • 36. Air Conditions, EMC and Grain Aeration Selecting proper ambient air conditions during fan operation hours is critical for avoiding overdrying during long term storage
  • 37. What happens to grain MC when aeration fan is turned on? Grain will slowly equilibrate with the ambient air condition based on the EMC relationship Corn at 14% MC 68°F and 60% RH 68°F and 80% RH 68°F and 70% RH Ambient air condition After enough fan run hours grain equilibrates to average air condition 12% MC 14% MC 16% MC Equilibrium Air RH%
  • 38. Reed Book Fig 18, p165 Wheat and Air Equilibrium at 12% Moisture Content 50 55 60 65 70 75 80 85 90 95 100 Air Temperature (F) 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 Absolute Humidity (lb water/lb air) 100 %Relative Humidity 50 %Relative Humidity Wheat 12 % m.c.
  • 39. Reed Book Fig 19, p166 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 50 55 60 65 70 75 80 85 90 95 100 Absolute Humidity (lb water/lb air) Air Temperature (F) 100 % Relative Humidity 50 % Relative Humidity Wheat 12 % m.c. Grain Temp = 95 ºF Air temp = 77 ºF Air R. H. = 80 % Air temp = 75°F Air R.H. = 80% Wheat with 12% m.c. at 95ºF aerated with air at 75ºF and 80% R.H. ==> What is the Twb of this air?
  • 40. Reed Book Fig 20, p167 Final temperature of wheat at 12% m.c. aerated with air at 75ºF Tdb, 80% R.H. and 70ºF Twb 50 55 60 65 70 75 80 85 90 95 100 Air Temperature (F) 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 Absolute Humidity (lb water/lb air) 100 %Relative Humidity 50 %Relative Humidity Wheat 12 % m.c. Initial Temp Cooling Air = 70°F Twb Final Grain Temperature 82°F Note: Grain Moisture Trend = 16.9%
  • 41. 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 50 55 60 65 70 75 80 85 90 95 100 Absolute Humidity (lb water/lb air) Air Temperature (F) 100 % Relative Humidity 50 % Relative Humidity Corn 16 % m.c. Wet-Bulb Lines Corn with 16% m.c. at 75ºF aerated with air at 60ºF and 50% R.H. Air temp = 60°F Air R.H. = 50%
  • 42. Final temperature of corn at 16% m.c. aerated with air at 60ºF and 50% R.H. and 50ºF Twb 50 55 60 65 70 75 80 85 90 95 100 Air Temperature (F) 0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 Absolute Humidity (lb water/lb air) 100 %Relative Humidity 50 %Relative Humidity Corn 16 % m.c. Wet-Bulb Lines Corn at 75 ºF Cooling Air = 50°F Twb Final Grain Temperature 54°F Air temp = 60°F Air R.H. = 50% Note: Grain Moisture Trend = 11.9%
  • 43. NEW Grain Aeration & Storage App
  • 44. NEW Grain Aeration & Storage App
  • 45. Aeration Decision Matrix Grain Moisture Content (%) Air-Grain Temp Difference (°F) Air much cooler than Grain Cooling decision criteria -5°F Air much warmer than Grain
  • 46.
  • 47. • Phase 1: Fall Cool Down • Lower grain temperatures stepwise • October 40-45°F • November 35-40°F • December 28-35°F • Phase 2: Winter Maintenance • Maintain temperatures with intermittent aeration • January, February 28-35°F • Phase 3: Spring Holding • Keep cold grain cold • Seal fans • Ventilate headspace intermittently S.L.A.M. Step 3: Aeration
  • 48. Rule of Thumb for Aeration Shrink Total Bushel shrink = Bu aerated x degree temp drop x 0.022 x 1.2% Example: • 50,000 bushel bin corn at 15.5% mc and 70°F • Cool to 50°F @ 75% = 264 bu of shrink during Oct cycle (15.2% mc) • Cool to 40°F @ 69% = 131 bu of shrink during Nov cycle (15.1% mc) • Cool to 30°F @ 64% = 131 bu of shrink during Dec cycle (15.0% mc) • Total Shrink = 526 bushels of aeration shrink • Expected final moisture content = 15.0-15.2%
  • 49. Moisture Loss due to Excessive Aeration of Corn 15.5% MC 15.5% MC 15.5% MC 15.5% MC 14.0% MC 12.5% MC 10.0% MC lb of water evaporated = loss of money 15.5% MC Instead of this Mostly end up like this
  • 50. Value of Corn Lost due to Over-Aerating 15.5% MC 14.0% MC 12.5% MC 10.0% MC Bin Size lb of water evaporated Bushel of water Loss of Money D60 H45 (103,000 bu) 165,744 2,960 $11,839 D84 H75 (334,000 bu) 537,216 9,593 $38,373 D105 H90 (626,000 bu) 1,007,280 17,987 $71,949 Calculated based on $4/bu of corn lb of water evaporated = loss of money
  • 51. EMC Controlled Aeration of Corn 15.5% MC 15.5% MC 15.5% MC 15.5% MC 15.2% MC 15.0% MC 14.8% MC 15.5% MC lb of water evaporated = loss of money Instead of this (Ideal) Achieve this (Practical)
  • 52. Shrink Loss Reduction for Corn Aeration Bin Size Uncontrolled Aeration Controlled Aeration Shrink Loss/year Shrink Loss/year 60 x 45 $11,839 $1,820 84 x 75 $38,373 $5,900 105 x 90 $71,949 $11,062 Uncontrolled Aeration Bottom Layer: 10% Top Layer: 15.5% Controlled Aeration Bottom Layer: 14.9% Top Layer: 15.5% Savings of 6X
  • 53. page 54 Aeration at any initial Corn temperature… Initial MC (%) 50°F / 60% 50°F / 80% 40°F / 60% 40°F / 80% 13.0% 50.4°F / 13.3% 54.0°F / 16.5% 41.0°F / 13.8% 43.9°F / 17.0% 13.5% 49.8°F / 13.3% 53.2°F / 16.5% 40.5°F / 13.8% 43.2°F / 17.0% 14.0% 49.1°F / 13.3% 52.5°F / 16.5% 39.9°F / 13.8% 42.6°F / 17.0% 14.5% 48.6°F / 13.3% 52.0°F / 16.5% 39.4°F / 13.8% 42.0°F / 17.0% 15.0% 48.0°F / 13.3% 51.4°F / 16.5% 38.8°F / 13.8% 41.5°F / 17.0% 15.5% 47.5° / 13.3% 50.9°F / 16.5% 38.5°F / 13.8% 41.2°F / 17.0%
  • 54. 12.7% MC 12.5% MC 12.3% MC 13.0% MC 11.5% MC 10.0% MC 8.0% MC 13.0% MC Moisture Loss due to Excessive Aeration of Soybean lb of water evaporated = loss of money Instead of this Mostly end up like this
  • 55. 13.0% MC 11.5% MC 10.0% MC 8.0% MC Bin Size lb of water evaporated Bushel of water Loss of Money 60 x 45 164,221 2,737 $21,896 84 x 75 532,278 8,871 $70,970 105 x 90 998,022 16,634 $133,070 Value of Soybeans Lost due to Over-Aerating Calculated based on $8/bu of soybeans lb of water evaporated = loss of money
  • 56. EMC Controlled Aeration of Soybeans 13.0% MC 13.0% MC 13.0% MC 13.0% MC 12.8% MC 12.6% MC 12.3% MC 13.0% MC lb of water evaporated = loss of money Instead of this (Ideal) Achieve this (Practical)
  • 57. Bin Size Uncontrolled Aeration Controlled Aeration Shrink Loss/year Shrink Loss/year 60 x 45 $21,896 $3,536 84 x 75 $70,970 $11,462 105 x 90 $133,070 $21,492 Uncontrolled Aeration Bottom Layer: 8.0% Top Layer: 13.0% Controlled Aeration Bottom Layer: 12.3% Top Layer: 13.0% Shrink Loss Reduction for Soybeans Aeration Savings of 6X
  • 58. Aeration at any initial Soybean temperature… Initial MC (%) 50°F / 60% 50°F / 80% 40°F / 60% 40°F / 80% 11.0% 50.2°F / 11.2% 54.9°F / 15.6% 40.5°F / 11.5% 43.3°F / 15.9% 11.5% 49.8°F / 11.2% 53.4°F / 15.6% 40.1°F / 11.5% 43.0°F / 15.9% 12.0% 49.3°F / 11.2% 52.9°F / 15.6% 39.6°F / 11.5% 42.4°F / 15.9% 12.5% 48.7°F / 11.2% 52.3°F / 15.6% 39.2°F / 11.5% 42.1°F / 15.9% 13.0% 48.4°F / 11.2% 52.0°F / 15.6% 38.8°F / 11.5% 41.7°F / 15.9% 13.5% 48.0°F / 11.2% 51.4°F / 15.6% 38.7°F / 11.5% 41.4°F / 15.9% 14.0% 47.7°F / 11.2% 51.1°F / 15.6% 38.3°F / 11.5% 41.0°F / 15.9% 14.5% 47.3°F / 11.2% 50.7°F / 15.6% 37.9°F / 11.5% 40.8°F / 15.9% page 59
  • 59. Predicting suitable aeration periods based on weather forecast… • NEW Grain Aeration and Storage App loads local 6-day weather forecast – Indicates average and minimum ambient temperature • Allows for selection of % of coolest hours available for next 6 days – 50% = selects the 50% coolest hours of each day, or all hours below the daily average temperature, and provides the recommended thermostat set-point temperature to achieve that target – 100% = maximizes fan run hours but results in a higher thermostat set-point temperature
  • 60. NEW Grain Aeration & Storage App
  • 61. Spring Aeration Should cooled grain be warmed up in the spring?
  • 62. Idealized Aeration Schedule ? Winter & Summer Holding Period
  • 63. Aeration cooling potential of corn & soybeans Des Moines – Iowa (2015-19; 5-year average) Average Temperature = 52.2 +/- 19.0°F Average Relative Humidity = 70.2 +/- 6.0%
  • 64. Des Moines – Iowa (2015-19; 5-year average) Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Aeration cooling potential of corn & soybeans Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73%
  • 65. Des Moines – Iowa (2015-19; 5-year average) Air EMC trend for corn & soybeans 15% 13% Average Temperature = 52.2 +/- 19.0°F EMC = 14.7% Corn Average Relative Humidity = 70.2 +/- 6.0% EMC = 13.2% Soybeans 47 F
  • 66. Des Moines – Iowa (2015 - 2019) Cooling potential of corn in November Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73%
  • 67. Des Moines – Iowa (2015 - 2019) Cooling potential of corn in February Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73%
  • 68. Des Moines – Iowa (2015 - 2019) Cooling potential of corn in April Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73%
  • 69. Des Moines – Iowa (2015 - 2019) Cooling potential of corn in July Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73%
  • 70. 135,000 bu Bin of Corn during Summer Storage in Indiana – Non-aerated on 7/28/89 8 10 10 10 10 10 10 12 1 2 12 14 14 14 14 14 14 14 16 16 16 16 16 18 18 18 18 20 20 20 20 22 22 22 2 2 22 24 24 24 24 24 2 6 26 26 26 26 26 28 28 28 28 28 28 3 0 30 30 30 34 r (m) z (m) 0 5 10 0 2 4 6 8 10 12 14 16 18 T(C) 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 7/28/1988 24:00 7/28/1989 24:00 13.8 14 1 4 14 14 r (m) z (m) 0 5 10 0 2 4 6 8 10 12 14 16 18 MC(%w.b.) 14.5 14.4 14.3 14.2 14.1 14 13.9 13.8 13.7 13.6 13.5 7/28/1988 24:00 7/28/1989 24:00 97°F 86°F 68°F 50°F 41°F 32°F
  • 71. Spring Aeration Should cooled grain be warmed up in the spring? NO!
  • 77. What about Aerated Grain Piles?
  • 78. Des Moines – Iowa (2015-19; 5-year average) Winter < 40°F Fall & spring = 50-60°F Summer = 60-77°F Continuous Aeration of a Grain Pile Winter R.H. = 70-75% Fall & spring = 60-73% Summer = 65-73% Average Temperature = 52.2 +/- 19.0°F  Oct-Mar = 36.2°F Average Relative Humidity = 70.2 +/- 6.0%  Oct-Mar = 71.3%
  • 79. Des Moines – Iowa (2015-19; 5-year average) Continuous Aeration of a Grain Pile 15% 13% Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F Oct-Mar = 71.3% EMC = 13.9% Soybeans 47 F
  • 80. Des Moines – USA (2016) Continuous Aeration of a Grain Pile 41 50 59 63 68 77 81 86 ~5 months when ambient temperatures are below 40°F for at least 300 h of aeration time each month (50% of time) Suitable airflow: 0.05-0.1 cfm/bu Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F Oct-Mar = 71.3% EMC = 13.9% Soybeans
  • 81. Des Moines – USA (2016) Continuous Aeration of a Grain Pile 41 50 59 63 68 77 81 86 ~6.5 months when ambient temperatures are below 50°F for at least 300 h of aeration time each month (of time) Suitable airflow: 0.05-0.1 cfm/bu Oct-Mar = 36.2°F EMC = 15.7% Maize Wet bulb = 32.8°F Oct-Mar = 71.3% EMC = 13.9% Soybeans
  • 82. Des Moines – USA (2016) Continuous Aeration of a Grain Pile 41 50 59 63 68 77 81 86 3 m x 30 d x 24 h = 2,160 hours Apr-Sep = 68.3°F EMC = 13.7% Maize Wet bulb = 61.7°F Apr-Sep = 69.0% EMC = 12.5% Soybeans
  • 83. Effect of continuous pile aeration on corn
  • 84. Effect of continuous pile aeration on soybean
  • 85. Summary – Managing Aeration Shrink Loss 1. Aeration cooling of grain follows the wet bulb temperature  line on the psychrometric chart 2. For given air properties, the dry bulb temperature the grain will cool to and the moisture content the grain will equilibrate towards can be calculated  based on equilibrium moisture content (EMC) and equilibrium relative numidity (ERH) relationship 3. Shrink loss due to aeration cooling can be calculated based on evaporative cooling effect 4. Shrink loss costs includes moisture loss and electric fan energy due to excessive operation
  • 86. S.L.A.M. Step 4: Monitoring • Temperature • Moisture • CO2 • Molds (cause spoilage and hot spots) • Insects • Mold feeders are an early warning • Population growth leads to “hot spots” • Late summer pest control (fumigation) • Rodents
  • 87. As a rule of thumb, one cable monitors a radius of 9 feet.
  • 88. Temperature Cable Placement Calculations • Sensors are typically 7 ft apart along a cable • Assume sphere with a radius of 3.5 ft around each sensor without overlap between sensor volumes, the three cable configurations would represent…
  • 89. Temperature Cable Placement Recommendations 1.5% 4.6% 10.8%
  • 90. 92 Results: 48x60 ft bin 3000 TCs 40oF 15 TCs 36oF 30 TCs 38oF 77 59 41 23 5 -13
  • 91. 93 Results: 48x60 ft bin 3000 TCs 40oF 15 TCs 36oF 30 TCs 38oF 3000 TCs 27oF 15 TCs 24oF 30 TCs 18oF 77 59 41 23 5 -13
  • 92. “No Cables” T/RH/CO2 Monitoring & Fan Control https://app.amber.ag/dashboard
  • 93. 95 Installation of the Amber Ag ACE Air Tools
  • 94. How does “no cables” sensing technology work? • Measures T, RH and CO2 of air in headspace above and/or plenum below the stored grain mass • Calculates EMC of the headspace or plenum air when fan is off or inlet air and exhaust air when fan is on • All sensors and fan controllers communicate as a stand alone cellular connection to the Amber cloud
  • 95. • Advantages: • Easy installation • Easy serviceability • Less expensive (11 cents/bu) • No cables in grain mass • No structural roof issues • Automatic fan control • No interference • Disadvantages: • No in-grain temperature and moisture sensing Summary: More Advantages than Disadvantages
  • 96. Amber CO2 monitor “No cables” T/RH/CO2 Monitoring & Fan Control
  • 97. “No cables” T/RH/CO2 Monitoring & Fan Control
  • 98. “No cables” T/RH/CO2 Monitoring & Fan Control
  • 99. Handheld carbon dioxide (CO2) sensors page 101 • Advantages: • Faster than T/RH sensors • No structural issues • Versatile use (bin, outdoor pile) • Disadvantages: • Hand-held • Cost: Telaire 7001: $459 https://www.microdaq.com/telaire-7001-carbon-dioxide-co2-monitor.php
  • 100. • Up to 600 ppm: stable grain at safe storage MC • 600-1500 ppm: on-set of mold growth • high grain storage temperatures • moisture condensation on grain surface, or • moisture infiltration into structure • 1500 to 4000 ppm: active grain spoilage • high biological activity in portions of grain mass • severe mold development, or • severe stored-product insect infestation Interpreting CO2 concentrations
  • 101. 1. Stored grain conditions can be monitored with temperature, moisture and CO2 sensors • Beware of number of cables and their placement 2. Regular monitoring of stored grain conditions allows for early spoilage detection and proactive operations management action 3. Early detection of spoilage using CO2 monitoring saves time and money • New “no cables” technology provides plug-n-play options and automated fan control Summary – Stored Grain Conditions Monitoring
  • 102.
  • 103. Quality Grain is Job #1!
  • 104. S.L.A.M. Best Stored Grain Management Practices • Prepare/clean your storage bins for new crop harvest • Dry grain then store at safe storage moisture content • Core & “un-peak” grain mass after loading bins • Aerate to cool grain (not shrink it) then seal fans • Manage headspace conditions with intermittent ventilation • Monitor grain regularly for CO2, surface condensation, temperature, insect activity, mold development
  • 105. Contact Information Dr. Dirk E. Maier, Ph.D., P.E. Professor of Grain & Feed Operations & Processing Agricultural & Biosystems Engineering Department Post-Harvest Engineer Iowa Grain Quality Initiative 3325 Elings Hall Iowa State University Ames, Iowa, U.S.A. dmaier@iastate.edu