NRRI Now Winter 1996

In Perspective by Michael J. Lalich, Director

This is an exciting issue for me. NRRI is "clicking" from an applied research and technology transfer standpoint. In this regard, several stories in this issue of NRRI Now demonstrate the scope of the Institute's programs and capabilities. Let me cite the efforts to develop flotation technologies at Minntac and adsorbent peat granules for Peat Technologies Corporation as illustrative.
The flotation research is perhaps one of the best possible illustrations of a successful applied research effort that I have encountered. It is often not enough just to research an idea on the laboratory or bench scale. It is frequently necessary, particularly in the area of process development, to follow up initial laboratory research with pilot scale testing that will lead to commercialization.
Challenging logistics and escalating costs of pilot scale activity often are major impediments to successful commercialization. In this case, imagine starting the research in a laboratory flotation cell that resembles a kitchen mixmaster. Then consider a year or so of testing in a three-inch diameter by twelve-foot high column at the Coleraine pilot facility.
Given the knowledge gained from this early research and pilot activity, consider the investment by USX to install a five feet diameter by 40-feet high column in the Minntac plant to test whether or not higher iron recoveries and more gangue (waste) removal could be achieved economically compared to conventional practice.
After initial frustrating results followed by determined efforts to verify the process with this larger in-plant column, imagine the satisfaction associated with the USX decision to install four 12-feet by 42-feet high columns to commercially treat the plant's entire production of approximately 13 million tons of concentrate per year. Understand also that the introduction of column flotation at Minntac opens the door for further research and plant improvements.
More typical perhaps of the type of the applied research/technology transfer activity one might expect of NRRI is the effort to develop and commercialize the granular peat sorbents. In this instance, NRRI researchers, recognizing the potential of peat as a filter and adsorbent, have over a period of years studies various formulations.
The peat granules were developed to overcome inadequacies of loose peat fibers and other types of compacted products. As may be expected, NRRI worked with the University of obtain patents and aligned itself with an entrepreneur, who in turn is licensing rights to the product from the University.
NRRI continues to work with the entrepreneur during plant start-up and to develop specific applications for the product. Although not required in this case, in similar situations the Institute frequently assists entrepreneurs and small businesses to develop business plans and procures start-up financing.
On a closing note, I can't think of a period where I've had more positive comments from clients, agencies, development professionals and community leaders alike regarding the individual talents and dedication of NRRI scientific and business staff throughout the entire Institute. Thus, I'd like to take this opportunity to congratulate my colleagues on a job well done.

Technology transfer improves iron recovery at Minntac

Technology to recover more iron from taconite in northeastern Minnesota developed and tested at the Natural Resources Research Institute Coleraine Minerals Research Laboratory ha snow been installed at the Mountain Iron USX Minntac plant.
The copper industry previously used column flotation to increase separation techniques to recover additional copper, but the taconite industry presently uses only conventional flotation cells, that is, until NRRI's Blair Benner applied flotation columns to the taconite industry's separation process.
"Think of a conventional flotation cell as a washing machine," said Benner. "There is an agitator and a tank with chemicals performing as soap attaching to the 'dirt,' silica. Air is added to make bubbles to float the silica away allowing the iron to settle to the bottom."
In a flotation column there is no agitator, the material enters near the top of the column and settles against an uprising stream of bubbles which carry the silica upwards and out of the column while the iron settles to the bottom. In addition the column uses a water wash at the top to help remove any fine iron trapped with the bubbles. The same chemicals are added to both types of flotation devices.
The application was first tested using a three inch diameter column 12 feet in height. This model successfully performed the removal of additional silica while trapping fine iron particles. Pilot scale tests stepped up to using an eight inch diameter column 22 feet in height. Finally a commercial testing of the columns occurred at Minntac using a five feet diameter column 40 feet in height. Based on positive test results, Minntac installed four columns each 12 feet in diameter and 42 feet in height to improve iron recovery.
"The project has had a favorable impact on iron recovery and has decreased our costs. The installation was made possible by the Investment Tax Credit Fund program supported by our Range delegation and the IRRRB," said J. E. Swearingen, general manager Minnesota Ore Operations.
"Changes in the taconite industry today are all cost driver," said NRRI's Coleraine Minerals Research Laboratory director Rod Bleifuss. "From a bench scale prototype at the research lab to full commercialization installed at Minntac, new/old ideas keep Minnesota's taconite industry globally competitive by holding costs downs."

Lakes, Rivers and Streams: Rough times ahead for the ruffe?

The ruffe (pronounced "rough") fish is more than just an exotic species. This Lake Superior invader has a price tag attached.
According to a recent economic analysis by the National Oceanic and Atmospheric Administration, the estimated loss of income to sport and commercial fishing due a fully-developed ruffe population in the Great Lakes could reach $120 million annually.
Minnesota Sea Grant funded a three-year, $491,356 grant providing funding for NRRI researchers to learn more about the ruffe and its reproductive behavior in an effort to control the expansion of this non-native fish.
Ruffe are "cousins" to native perch and walleye and pose a great threat to sport fish and the entire ecosystem in the St. Louis Harbor. Ruffe are adaptable and just plain out compete native species.
According to recent trawls (April-September 1995) IN THE St. Louis Harbor, ruffe outnumber all other species by a two-to-one ratio. That means over 50 percent of all fish in the harbor are ruffe. And that number may grow rapidly. Loch Lomond, Scotland, experienced a ruffe explosion from 12 to 90 percent of the total fish community over a seven year period. During that same time frame, the European perch population decreased by 88 percent. Faced with these intimidating numbers, scientists are eager to interrupt the ruffe's takeover.
"Reproduction requires a carefully choreographed set of behaviors, and we want to throw a monkey wrench in the whole thing," said NRRI cell biologist Patrick Schoff.
By studying the ruffe's mating behavior, understanding their pheromone (olfactory signals) molecular structure and synthesizing their reproductive pheromones, researchers hope to influence ruffe reproduction. These steps, over time, will help save native species from being outnumbered.
By obstructing the olfactory signaling between the female and the male and similar signaling between eggs and sperm, ruffe spawning and reproductive cycles could be interrupted.
"We are at the very beginning of understanding ruffe biomolecular makeup and reproduction and being able to affect the ruffe with affecting the game fish is the key," said Schoff. "We assume that fertilization will be much less effective if we 'set' pheromone traps."
This method, pheromone trapping, has been successfully used in several insect control programs. "Reproductive control has been one of the most effective pest control methods devised," said Schoff, "and ruffe are good reproducers." Considering the price tag attached to the ruffe, pheromone trapping seems to be a viable approach to control.
Schoff is collaborating with Jon Holy, University of Minnesota Duluth School of Medicine, Peter Sorensen, University of Minnesota Department of Fisheries and Wildlife, and Peter Thomas, University of Texas Marine Science Institute. In addition, the Fond du Lac Natural Resources and the National Biological Service are both contributing effort to the ruffe collection and testing.

Forests and Wildlife: Migration patterns studied

Birds and propellers make a bad combination. In a proactive stance, a new study funded by the American Wind Energy Association and Legislative Commission on Minnesota's Resources (LCMR) seeks to avoid a problem before it occurs.
Before the turn of the century, renewable energy sources are required to be explored in an agreement with the Northern States Power nuclear energy facility. While wind turbine farms are not stopped by collisions with birds, bird populations can be decimated if the turbine farms are located in areas that the birds normally use. A two year, $195,000 study awarded to the Center for Water and the Environment will determine the best locations for wind turbines that would impact bird populations the least.
Avian ecologist JoAnn Hanowski heads the study assisted by Kent Montgomery and Rita Hawrot. During four sampling periods (two during the spring and two during the fall migration) in eight locations in western and southwestern Minnesota patterns of movement that could interfere with wind turbines were studied.
Sites are monitored 16 hours daily as birds tend to move in the early evening or early morning hours. Researchers know that birds use consistent local corridors to migrate from feeding to nesting areas. By identifying these corridors, the information gathered will eliminate broad areas from development of wind turbine farms. The monitoring sites are primarily for local migrations because mass migrations in the fall are at a much higher altitude and would probably not interfere with the turbines.
"There are no studies monitoring bird movement this extensive in this area of the state," said Hanowski. "We hope to use this information to develop a landscape model using geographic information systems to predict areas of high bird use based on landscape configurations to provide rules for avoiding bird/propeller collisions."

Peat: Technology transfer creates new business

Worldwide, almost one billion gallons of contaminated substances flow daily from large municipalities into nearby lakes, rivers and streams. Today, a cost effective, environmentally sound solution is now being produced by a new company just south of Eveleth, Minnesota.
Peat Technologies Corporation, with CEO Roy Larson, is manufacturing peat granules that will extract metal and organic contaminants from wastewaters based on successful research conducted at the Natural Resources Research Institute.
Researcher Tim Hagen explored alternative uses for Minnesota peat, a long-underutilized, renewable resource. Peat sorbents are effective at removing hydrocarbons from land and water, and Hagen applied the same principles for removal of heavy metals such as lead, cadmium and mercury; all highly toxic compounds frequently found in wastewaters. Wastewater including the contaminants from municipalities and industry contribute to water quality problems. Storm water runoff and sewage overflow also increase contamination in surface waters.
Larson notes that the market for his product, MultiSorb 100(tm), has worldwide potential. "We're working with a Japanese agent, Sanko, to present our technology to several Japanese companies. They're halfway through their rigorous testing and we're optimistic about their responses. Currently, we're working with U. S. engineering firms and chemical companies. In addition, companies in South Africa have expressed interest in using the peat granules to recover nickel from wastewater. Future potential could include recovering gold through the same process," said Larson.
Minnesota's peat acreage is one-third of the total acreage in the lower 48 states. "By managing this resource carefully and pursuing high-value applications, the Minnesota peat industry can become a worldwide competitor," said Hagen.

Minerals: Building with industrial waste

As we embark on the 21st century, value-added products are an important part of Minnesota's economy. Environmental Brick Corporation (EBC) of Goodhue, Minn., recently began a venture with NRRI and several regional manufacturers to develop quality bricks and other construction-grade materials form industrial waste.
Previously such materials as paper mill sludge and various types of bottom and fly ash were considered waste products; now they may find a second life as brick ingredients.
EBC founder, Gordy Jarvis, Marv and Mel Bollom, generated the recycled brick idea and asked NRRI for help. Initially researchers ran strength tests on prototype bricks but now are more involved with the actual development process. The NRRI machine shop developed a die and the mechanism that will create the bricks and pavers.
NRRI researcher Larry Zanko is coordinating the project while Julie Oreskovich, laboratory technician, will conduct ASTM and compositional test. In addition, NRRI's Coleraine Minerals Research Laboratory will run leach tests. This type of compositional testing is set by the EPA and determines if materials will release potentially hazardous metal levels when exposed to the environment. Leach tests are especially important with recycled products and will be conducted both prior to and after the manufacturing process.
"Not only do the raw materials (the sludge and fly ash, etc.) have to pass muster for suitability, but they have to pass tests for environmental safety," said Zanko. "And, on top of everything else, the economics have to be there; the brick manufacturing must be viable."
EBC owners will also work with NRRI business specialist Kathy Forslund for market analysis and a marketing plan. EBC's concept is especially attractive because it keeps waste materials from landfills, thus saving environmental hazards and money, and it creates a value-added product that is generated, then recycled, all within the same region.
In addition to assistance provided by NRRI through Minnesota Technology Inc. funding, both Environmental Brick Corporation and North Shore Mining have contributed funding for this initial research.

Forest Products: Rural jobs created by new product

Down where the corn grows "knee-high" by the fourth of July, a new company, Co-Pak, Inc., is starting to make the world a cleaner place, with corn stalks.
Minnesota corn, or more accurately, corn stalks will be put to work in machine shops soaking up oil spills via a new manufacturing plant in Wanamingo, Minn.
Larry Berg's company, Co-Pak, Inc. will lease building from the City of Wanamingo to start a manufacturing facility. Berg, along with NRRI, invented the patented board and production will start in spring of 1996 initially employing six people.
Berg started exploring uses for corn stalks with the Agricultural Utilization Research Institute (AURI) almost five years ago. After working with AURI research Bill Stoll on various products made with corn residues, Stoll put Berg in touch with NRRI to explore the possibility of creating a board from corn residues.
Berg and NRRI composites engineer Brian Brashaw worked together making the first prototype with initial funding provided by AURI.
AgriSorb is a textured mat that resembles fiberboard but is made from corn stalk residues. Test results showed that AgriSorb soaked up as much as two quarters of oil per square foot without releasing any oil. Additionally, AgriSorb can be incinerated by certified waste facilities.
Minnesota Technology, Inc. provided funding to NRRI to assist Berg during commercialization activities. This funding allows NRRI researchers Bob Vatalaro, Chris Edwardson, Tim Hagen, Steve Kossett and Brashaw to continue providing on-site technology transfer during the initial manufacturing phases.
AgriSorb manufacturing could also provide an additional market for corn farmers to increase revenues by selling the stalks after harvesting.

Business success: Husky Panel Systems Inc. enters new market

When entrepreneurs Chuck and Dick Mizia started Husky Panel Systems four years ago, they could only dream that they would see their new product on a 35-room motel.
Now, thanks to a collaborative efforts between the Mizias and NRRI, the new Country Meadows Inn of McGregor, Minn., will feature the north woods look while using 90 percent less lumber than conventional log siding.
Husky Panel Systems, a Duluth-based manufacturer of Husky Half-Log(tm), began with an idea to create a log-look siding product while using the minimum amount of Minnesota's resources. That's when a friend steered the Mizias to NRRI. After completing NRRI's Entrepreneurial Development Program offered through the NRRI/UMD Center for Economic Development, the Mizias began to create their prototype with wood scientists, Chris Edwardson. Through the work completed at NRRI's pilot plant, the Mizias' plan began to take shape. Thus, Husky Panel Systems was born.
Since 1991, Husky Panel Systems has sided several homes, developed and expanded their product line to include a wood-veneer log, and offered their stock on the public market. Now, four years later, Husky Panel Systems is entering a new arena, the resort/tourist market. This third niche follows the Mizias' business plan that began with remodeled homes and new construction. The resort/tourist market also demonstrates the flexibility and affordability of the Husky Half-Log(tm).
The Husky Half-Log(tm), a product of engineered wood adhered to foam insulation and molded into a log shape, creates the authentic north woods feeling that resort clients love. "Country Meadows Inn will have that rustic exterior in a northern setting," Chuck Mizia said.
Howie and Alice Pickles, owners of Country meadows Inn, agreed. "We wanted that log look," reported Alice, "and Husky provides that." In addition to its aesthetic value, the Husky Half-Log(tm) offers insulation values four times greater than competing solid wood products and weights 70 percent less than conventional logs. For Country Meadows Inn, those numbers translate into wise resource consumption and energy savings in addition to about 10 new jobs for the McGregor area.
Creating jobs is nothing new to NRRI's business group staff that assisted over 23 Arrowhead Region entrepreneurs in 1995 alone.
"It booted us into the starting block; it gave us a focus," Chuck Mizia said of NRRI's Entrepreneurial Development Program.
Kathy Forslund, NRRI business specialist, picked up where the Entrepreneur Program ended. By helping the Mizias create a sound business plan, both on paper and financially, Forslund gave Husky Panel Systems the power to stand on its own. And the Mizias haven't looked back.
Editor's Note: Country Meadows Inn opened in early 1996 and employs about 10 full- and part-time employees. The motel features 35 rooms, an indoor pool, hot tub, and sauna. The motel is located on the northwest corner of Minnesota highways 65 and 210 in McGregor.

Incubator: Two Harbors facility scheduled to open in spring

When a small northeastern Minnesota community wants to attract industry to town, cooperation of many organizations and individuals make it happen.
After three years of planning, the Two Harbors community will open to Northshore Business Enterprise Center (NSBEC) in the spring of 1996.
Business incubators, such as the Two Harbors facility, are providing a boost to new companies by sharing services such as receptionists, phones, office equipment and a business development specialist to oversee typical business problems and provide advice/assistance to business first-timers.
Mission for the NSBEC noted NRRI business group director Lee Jensen, is to foster entrepreneurship, encourage business startup and to expand and diversify the Two Harbors area economy.
Four companies have inquired about space in the center according to board president and NRRI researcher Gene Betts. With 17,000 square feet space, the center encourages inquiries from new companies for 1,000 to 10,000 square feet of space.
Organizations such as the Iron Range Resources and Rehabilitation Board, NSBEC, United Power Association, Co-op L and P, HRA, Natural Resources Research institute, Two Harbors Development Commission, Lake County, United States Department of Agriculture, Small Business Development Center and UMD Center for Economic Development cooperated to create the center.
Allen Jackson, a business development specialist was hired in December to provide technical assistance to small businesses and entrepreneurs serving Lake, Cook and Northern St. Louis counties from NSBEC after it is completed this spring. Jackson formerly owned and operated his own small business for 18 years and was also the director of the Hibbing Small Business Development Center. His expertise is in business planning, market research, new product development, financial analysis, access to capital and loan packaging.
"I'd like to encourage all entrepreneurs and small businesses in Lake County to contact me for any of these services," said Jackson. He can be reached at (218) 834-3494.

NRRI and the community: Collaborative research leads to alternative wastewater treatment systems

The controversial issue of wastewater treatment touches the everyday life of every Minnesotan, failing wastewater systems may affect our health, our water, our soil, and our future. Over one-fourth of all residents depend on either individual or small community on-site sewage treatment systems.
While conventional systems are failing at an alarming rate, researchers at NRRI are participating in a statewide study to look at alternative wastewater treatment methods. By combining the knowledge gained from NRRI's researchers with other experts in both the public and private sectors, the citizens from the land of 10,000 lakes will have the answers from the best.
The project covers research at both a northern site, in St. Louis County, and at a southern site in LeSeuer County. The northern site currently encompasses two study sites near Duluth: one at Grand Lake and the second at the Northeast Regional Correction Center (NERCC).
Residents of Grand Lake, Minn., are already benefiting from this project. "I feel a lot better about the wastewater we produce," said lake resident and registered nurse, Wanda Simmonds. "And I think we'll see a difference in the quality of the lake. What they (the project coordinators) have done is just amazing. This alternative system has given us so much more freedom."
The Grand Lake site typifies many situations around Minnesota. Residents live close to a body of water where the water table is close to the surface. The soil, which should act like a filter, quickly becomes saturated with sewage.
"The situation at Grand Lake is not uncommon," said NRRI soil scientist Barb McCarthy. "Until now, lakeshore residents like those at Grand Lake had only one option, holding tanks, which are extremely costly."
The Grand Lake study site consists of a constructed wetland built tot service the wastewater needs of about 10 lake homes. The wetland system mimics the process occurring in natural wetlands, but concentrates it in a smaller area. This particular wetland consists of two cells, The first cell resembles a natural stand of cattails and breaks down organic matter, filters solids, destroys disease-causing microorganisms, and removes most nitrogen and some phosphorus from the wastewater. The second cell then disperses this treated water into the soil while providing additional treatment.
Lakeshore residents throughout Minnesota are especially susceptible to problems resulting from failing septic systems. Poor treatment means more than just noxious odors; it also poses public health threats from both exposure to raw effluent (the water that flows from a treatment system) and from contaminated groundwater, the main source of drinking water. Failing systems also mean that the lake's water quality is likely to degrade, and that's a situation no one wants.
NRRI researchers hope this project, funded in part by Minnesota Technology, Incorporated, and the Legislative Commission on Minnesota Resources will provide several alternative treatment systems. In fact, NRRI researchers are simultaneously examining seven different methods at the NERCC site: constructed wetlands; peat filters; intermittent sand filters; recirculating sand filters; granulated peat filters; a standard trench system; and drip irrigation to be installed this spring.
"The NERCC site is an excellent way to look at alternative treatment systems in a side-by-side comparison using the same wastewater," said McCarthy. "This study will put all of these technologies on the same playing field." While all of the alternative systems are in various stages of research, the drip irrigation system has great potential for northern Minnesota residents. Similar to a soaker hose, this new method evenly distributes wastewater into the soil from a tube. This is especially useful in situations with rock soil or dense forests. "We are trying to demonstrate that alternatives to conventional systems can work effectively in northern Minnesota's severe climate, while determining their costs and developing design criteria to allow technology transfer to the private sector," said Rich Axler, NRRI's water quality specialist.
NRRI's researchers, working with St. Louis County Health Specialist Jeff Crosby, will compare the performance of five northern systems to similarly-designed systems built by University of Minnesota researchers at the LeSeuer County site.
The northern research sites have already generated much local interest from both local businesses and agencies as indicated by donated labor and supplies.
This collaborative effort also includes the Western Lake Superior Sanitary District (WLSSD), which will provide laboratory analysis at both northern sites in addition to donating supplies and technical assistance. In addition to McCarthy and Axler, the project includes a cross-section of other NRRI researchers: Steve Monson-Geerts, Jerry Henneck, Del Nordman, and Tim Hagen.

IRRRB Study
Individual homeowners are not the only group concerned about wastewater treatment. Many Minnesota resort owners are facing expensive replacement of failing systems. In response, the Iron Range Resources and Rehabilitation Board Northern Lights Tourism Alliance is sponsoring research of viable wastewater options for Minnesota Taconite Tax Relief Area resorts. NRRI's McCarthy is directing this project which will be featured in the 1996 Spring issue of NRRI Now.

Project Highlights

Avian research continues
The Legislative Commission on Minnesota Resources has renewed its commitment to increase the understanding of how forest harvesting and management affect forest birds by continuing funding through 1997 with $368,000. The project aims to reduce future conflicts in forest use.

New product line added to McGregor business
Minnesota Specialty Products has added natural berry wines to its Minnesota Wild(tm) products. The company will sponsor a grand opening event in McGregor, Minn. The company was founded in 1990 with business and marketing assistance from the Center for Economic Development and the NRRI Business Group.

Business expansion
The personal touch, mass mailing company, Irresistible Ink, Inc. has expanded its northeastern Minnesota operation to include a new facility in Ely Minn. The NRRI Business Group assisted the company with its expansion plans and loan applications.

New research program
NRRI has recently added a new research program to the forest products division. The program includes a membrane press donated by Northern Contours of Fergus Falls Minn. and will enable the division to stay at the cutting edge of technology.

Prop Shop expansion
Northern Exposure Manufacturing, doing business as The Prop Shop, has recently added a small, easily-maneuverable pontoon boat to its existing product line with business assistance by the Business Group.

Water testing application studied
Water quality sampling technology is being studied by NRRI researchers in conjunction with an industrial partner, A. W. Research of Brainerd, Minn. Patent considerations are being examined.

Hybrid poplar environmental impact
The U. S. Forest Service awarded NRRI forestry a one-year, $94,860 grant to compare the environmental impacts of hybrid poplar plantations to agricultural crops.

The Natural Resources Research Institute was established by the Minnesota Legislature in 1983 to foster economic development of Minnesota's natural resources in an environmentally sound manner to promote private sector employment.

Michael Lalich, director
Center for Water and the Environment: Gerald Niemi, director
Center for Applied Research and Technology Development: Thys Johnson, director
Center for Economic Development: Kjell Knudsen, director

NRRI Now
Nora Kubazewski, editor
Brenda Maas, writer