[Rhodes22-list] Winter Semester, 2004 @ SVSU - The Nerdy Adventure Continues!

[Roger Pihlaja]

Bill,

It's not just a matter of cost effectively "disposing" of the residual mash.
At the moment, the only major use for this material is as animal feed and
small amounts are sold as a protein supplement for humans in health food
stores.  The animal feed market is already saturated and there are plans
underway to double alcohol fuel production in the next couple of years.
When that happens, there won't be enough livestock on the planet to consume
that much DDG!  But, on a dry basis DDG has more energy/lb in it than wood!
The major problem will be that DDG has a large protein content.  Proteins
contain organic nitrogen as part of their molecular structure.  Unless this
organically bound nitrogen is combusted under specific conditions,
combustion of proteins tends to give off a lot of NOx emissions.  Thus, the
DDG combustor design is going to have be very special, with a reducing
(oxygen starved) inlet section followed by an oxydizing (oxygen rich)
afterburner section.  I believe my design will be generally useful for
recovering energy from a large number of biologically derived waste
materials, such as sugar beet pulp, cotton waste, waste wood, sawdust, etc.

I expect there will be a lot of prior art in this area, which is why so much
of the research project is devoted to literature, patent, and vender
searching.

Roger Pihlaja
S/V Dynamic Equilibrium

----- Original Message -----
From: "Bill Effros" <bill at effros.com>
To: "The Rhodes 22 mail list" <rhodes22-list at rhodes22.org>
Sent: Saturday, November 29, 2003 10:02 AM
Subject: Re: [Rhodes22-list] Winter Semester,2004 @ SVSU - The Nerdy
Adventure Continues!


> Roger,
>
> As I understand your project, you are trying to develop a cost effective
method for disposal of "mash" after extracting alcohol from corn.  It seems
to me there should be ample funding available from non-traditional sources
who have been trying to solve this problem ever since liquor tax statutes
were enacted.
>
> Maybe there is someone on the list who could help you "network" with these
individuals.
>
> In the meantime, there are many books available on the topic.  Here is
one:
>
> Chesapeake Rum Runners of the Roaring Twenties Eric Mills $26.00 CORN RUM
>
> Bill Effros
>
>
> ----- Original Message -----
> From: Roger Pihlaja
> To: The Rhodes 22 mail list
> Sent: Friday, November 28, 2003 11:15 AM
> Subject: [Rhodes22-list] Winter Semester,2004 @ SVSU - The Nerdy Adventure
Continues!
>
>
> Hi Everybody,
>
> Well, as you can tell by the subject title, this post is not about
sailing.  If anyone is bothered by the idea that I would use this forum to
tell my sailing friends about what is going on in my life; then, simply hit
delete now and move on rather than do more complaining about modifying the
list's charter.
>
> I finally have my class schedule in place for the Winter Semester, 2004 at
Saginaw Valley State University (SVSU).  My classes are going to be:
>
> ME380 (3 credit hours)  Manufacturing Processes & Systems  (Mon & Wed
11:30 AM - 12:50 PM)
>
> ME451 (3 credit hours)  Machine Design  (Tue & Thur 10:00 AM - 11:20 AM)
>
> ME480 (3 credit hours)  Senior Design I  (Tue & Thur 9:00 AM - 9:50 AM +
Thur 1:00 PM - 3:50 PM)
>
> ME497 (3 credit hours)  Sr. Research Project, Sponsor: Dr. Christopher
Schilling + The Michigan Corn Grower's Association,
>               Research Project Title: "Biowaste Energy Recovery", Expect
To Publish A Paper In A Peer Reviewed Journal,
>               Days & Times At My Convenience As Long As Total => 9
hours/week
>
> MSTP531 (3 credit hours)  Entrepreneurship Seminar, (Wed 4:00 PM - 6:50
PM)
>
> This is a much easier class schedule than the 17 credit hours I'm
currently struggling with.  There are no lab classes like the two I have
this semester.  Although labs are only 1 credit hour apiece, they meet for 3
hours/week and require a lot of preparation + writing lengthy technical
reports.  The time and effort required for these labs is all out of
proportion to 1 credit hour.  In effect, my class load this semester is like
taking 21 credit hours of nonlab classes, which is really heavy.  Next
semester's daily schedule will also be much easier than my current class
schedule from a time spent on campus point of view.  I currently have
classes until 10:00 PM, three nights/week followed by a 45+ minute drive
home.  Next semester, my latest class will get out at 6:50 PM on Wednesdays.
The rest of the week, I will be finished with my classes by late afternoon.
>
> ME380, ME451, & ME480 are all on the normal mechanical engineering
schedule of required classes.  However, the other two classes had to be
petitioned in for credit in my major.  You see, I have a plan; both for
graduation as well as what I might potentially do after getting my BSME
degree.
>
> Note ME497, the Sr. Research Project.  My research sponsor, Dr. Schilling,
teaches the "Principles of Engineering Materials" class that I am currently
taking.  Dr. Schilling and I have become pretty good friends over the
semester.  Dr. Schilling is into research into new biologically-derived
polymers and recovery of energy from biological waste materials.  A lot of
his work is externally funded by the Michigan Corn Grower's Association.  I
leveraged my expertise in chemical engineering and process development into
an idea for recovery of energy from the waste material that is left over
after corn is fermented to make alcohol.  This bio-sludge is currently dried
at great expense and then sold at a loss as an animal feed called
Distiller's Dry Grain (DDG).  It turns out that DDG has a lot of energy in
it and may be more valuable as an alternative fuel to help offset the energy
requirements of the alcohol process.  The research project next semester
will involve a detailed process design, mass and energy balance modeling,
economic modeling, vender, literature and patent searches.  Dr. Schilling
and I expect to coauthor and publish a paper by the end of the semester.
So, that will look pretty good on the old resume even if nothing else comes
of this project.  Most of the work will be in the library and on the
computer.  As long as I put in at least 9 hours/week on this project and
keep Dr. Schilling informed of my progress &/or any problems, I can pretty
much come and go as I please.
>
> Note MSTP531, the Entrepreneurship Seminar.  This is a graduate school
level class that is open by invitation only.  I had to go thru an interview
with the professor, Dr. Thomas Kullgren, in order to get an invitation to
take the class.  One of the prerequirements for this interview was the
preparation of an idea for a new start-up business that will become the
basis for the study in the class.  My business plan was to form an
engineering consulting and construction company that would custom engineer
systems like the energy recovery from biowaste process described above,
purchase off-the-shelf pieces/parts from other venders, perhaps design and
build a few special pieces/parts in house, assemble and sell these systems
as package, turn-key solutions to industry.  The literature, patent, and
vender searches I will be doing in my ME497 Sr. Research Project will
fundamentally support the work going in this class.  By the end of the
Winter, 2004 Semester, I should have a pretty good idea whether this plan is
a potentially viable start-up business or not.  Whether this particular plan
is a good one or not, I will still be better off for having gone thru the
decision making process as part of this entrepreneurship seminar.
>
> Note ME480, Senior Design I.  This class is considered the "Capstone
Design Class" of the entire mechanical engineering program at SVSU.  In this
class, the students are divided into teams that are supposed to come up with
an idea for some mechanical gadget that is not currently on the market and
do a detailed engineering design.  In ME481, Senior Design II, which I will
be taking in the summer, the same teams have to build a working prototype of
their device.  The idea behind these two classes is that senior students are
supposed to demonstrate their mastery of all the tools and expertise which
they will need as professional mechanical engineers.  I've already found a
partner for the Senior Design series.  Her name is Christa and she's a
transfer student from Kettering University in Flint. MI.  Christa is in a
couple of my classes this semester and also plans to graduate in August,
2004.  The biggest challenge in the Senior Design series is coming up with a
project to work on.  In past semesters, some of the projects have been
gadgets to make life easier for handicapped people.  Dr. Brooks Byam teaches
the ME480 - 481 series and is also the faculty advisor to the SVSU Formula
Car Racing Team.  A lot of the previous projects have been associated with
designing and building components for the race car.  These projects are OK,
but Biowaste Energy Recovery is much more interesting to both Christa and I.
I've spoken to Dr. Byam about my idea for a process to recover energy from
biowaste.  We've agreed the entire process would be too big a project for
this class.  However, the process as I've envisioned it, will require some
sort of final dryer to get the last of the moisture out of the biowaste just
prior to burning the biowaste to produce energy.  Our project will be to do
the engineering design of this dryer.  The literature, vender, and patent
searches plus mass and energy balance modeling from my ME497 Sr. Research
Project will fundamentally support this effort.  If all goes well, in ME481
Senior Design II, this next summer, Christa and I will build and operate a
working scale-model prototype dryer that will generate scalable drying
kinetics data for these biowaste materials.  So, I've even managed to adapt
one of the required courses in my major to serve my own needs and agenda.
Actually, the dryer should be a wonderful Senior Design project.  After all,
it's a machine with moving parts that have to process a difficult to handle
semi-solid sludge.  There will be heat transfer issues, material handling
issues, materials of construction issues, possibly corrosion and high
temperature operation issues - in other words, a real challenge and a great
project!  Dr. Byam also appreciated the fact that Christa and I will be
coming into his class with our project already scoped out as opposed to the
majority of senior students that struggle with this issue for most of the
semester.
>
> So, there you have the nucleus of my end-game plan.  9 out of 15 credit
hours in the Winter 2004 Semester will be associated with my plan to
potentially form a new business.  As you might imagine, the SVSU faculty are
excited about the idea that one of their students might create a new
start-up business based upon work done in their classes.  They are all
behind me 200%!  I don't know where all this is going to end up by next
August.  But, it won't be boring!
>
> Roger Pihlaja
> S/V Dynamic Equilibrium
>
>
>
>
>
>
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