Kingsly Ambrose, Ph.D., Assistant Professor, Grain Science and Industry Department, Kansas State University

1. Bulk Solids Research & Outreach Programs
Kingsly Ambrose
May 08, 2014

2. • The first land-grant institution in
the U.S., founded in 1863
• Over 23,000 students enrolled in
more than 200 undergraduate and
100 graduate programs
Kansas State University

3. • Formed out of the Department of Chemistry in 1910 to address
the growing needs of the “modern” milling industry
• Only university-based program in the world that offers the
combination of UG and graduate degree programs of its kind:
– BS Milling Science and Management
Bakery Science and Management
Feed Science and Management
– MS/PhD Grain Science
Department of Grain Science & Industry

4. • Range from a bench scale mill (0.5 kg/h) to pilot mill (1 MT/h)
– Batch vs. continuous
– Scale & complexity
– Level of technology
• Teaching lab: Experimental mills (table top Ross mill, Brabender Junior and
Senior, Buhler, Miag), hammer mills, ball mill, attrition mill.
• Specialty dry mills (purify, fractionate, and grind and seed-like material,
including cereals, pseudocereals, legumes, pulses, spices, gums)
• Flour & dough testing, cereal chemistry and research labs
Grain Processing Facilities

5. Principles of Milling - Teaching Labs

6. Hal Ross Flour Mill

8. International Grains Program (IGP)
• 20,000 square feet
• State-of-the art audio/visual capabilities
• $4 million project funded largely by
Kansas crop producers

9. • Comprehensive extrusion lab to continue specialization on snacks, ready-to-
eat breakfast cereals, pet foods and aquatic feeds
• Advanced fermentation methods
• Industrial application of cereal grains and oilseeds
• Client laboratory and office space
Bioprocessing and Industrial Value-Added Program (BIVAP)

10. • Latest industry technologies
(cleaning and peeling, color-sorting,
roller mills, sifting and pneumatics)
• Hard, soft and Durum wheat
• Whole wheat milling
• Specialty milling of corn and
sorghum
• Simulate various mill flow lengths
• Flexible equipment research area
Hal Ross Flour Mill

11. • Teaching, research, service facility
• Science and education wing
• $13.5 million project
O.H. Kruse Feed Technology Innovation Center

12. Bulk Solids Teaching, Research
and Outreach Programs

13. Teaching
• Undergraduate courses
– Bulk Materials Handling
– Pneumatic Conveying of Dry Solids
• Graduate courses
– Particle Technology for Solids Handling and
Processing
• Distance Learning
– Preventing and Responding to Grain Dust
Explosions (GEAPS/KSU distance learning; 1 CEU)

14. Research
• Surface properties
• Bulk flow characterization
• Particle modeling
‒Particulate Flow and Materials Handling
‒Process Modeling and Simulation

15. Surface Characterization of Solids
• Surface chemistry
• Liquid bridging
• Surface roughness, surface energy, cohesion
‒Sifting characteristics; caking
Collaborator
Liquid bridging
Surface fat in
wheat flour
AFM image of
wheat flour

16. Flow of Solids
• Effect of impurities on bulk flow of grains
• Flow characteristics of Dried Distillers Grains
with Solubles (DDGS)
• Evaluating the flow of pet-food ingredients
Sponsors:

17. Particle Modeling
• Modeling the wheat milling process
Collaborator:

18. Particle Modeling
• Flow of grains in a continuous grain dryer
Sponsor:

19. Particle Selection

20. Particles Positions
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.25
2.30
2.35
2.40
2.45
0.0 0.5 1.0 1.5 2.0 2.5 3.0
PositionZ:Width(m)
Time (s)
From Column 7 (Middle) Position Z: Width (with
Stiffeners)
Position Z: Width
(without Stiffeners)

21. Heat Transfer Modeling
• Cooling pattern of dried distillers grains with
solubles (DDGS)
Sponsor:Predicted temperature
profile when cooled to
296.15 K
DDGS Pile

22. Grain Dust
• Quantifying cohesive force
• Grain dust dispersion pattern

23. o Grain dust explosion incidents data collection and
reporting
o Grain dust explosion prevention workshops
o For workers/supervisors
o Basics on combustible dust (4 hr)
o Advanced mitigation methods (3 hr)
o Trained about 500 workers/supervisors
Source: edn.com
Outreach Activities
Sponsors:

24. Short Course on Bulk Solids Handling, Storage
• Venue: Department of Grain Science and Industry
• Date: 27-30 October, 2014
• For registration: http://www.grains.k-state.edu/igp/
• Collaborators (2013): Purdue University; Dow
Chemical Co.
• Sponsors/collaborators (2013)

25. Short Course on Bulk Solids Handling, Storage and Flow

26. Current
• Experimental Milling Facilities (wheat, specialty crop)
• Powder Rheometer
• Moisture sorption analyzer
• Lab-scale and pilot-scale hoppers for flow testing
• Density measurements
• Software
• Discrete Element Modeling
• ANSYS FLUENT
Particle Technology Lab Facilities

27. Bulk Solids Innovation Center
• K-State’s new initiative
• Research, education and testing facility @
Salina, KS
• In collaboration with K-Tron

28. Thank You!
kingsly@ksu.edu
Ph: 785-532-4091
http://www.grains.k-state.edu/particle_technology/Home.html