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www.sustoil.org 9 th June 2010

www.sustoil.org 9 th June 2010. Contents. Improving the production and yield of oil crops oilseed rape (FERA, UK) David Turley and Ruth Leybourne sunflower (CETIOM, France) Alain Quinsac and Francis Flénet Utilization of by-products

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www.sustoil.org 9 th June 2010

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  1. www.sustoil.org 9th June 2010

  2. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Alain Quinsac and Francis Flénet • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  3. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Francis Flénetand Alain Quinsac • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  4. Oilseed rape (OSR) • EU largest producer in the world • 18,000,000 t • Average EU yield: 3-3.3 t/ha • Other producers • China • 11,000,000 t (1.8 t/ha) • Canada • 9,500,000 t (1.8 t/ha) • India • 6,500,000 t (0.8 t/ha) • OSR production: 70% of all oilseeds within EU27

  5. EU average yields 800,000 t

  6. Increasing yield of OSR/ha • Selective breeding, genetic manipulation, better management practices could lead to a yield of 6.5 t/ha • Develop improved cultivars • Optimise the seed number per unit area • Increase the solar radiation efficiency (reduce interference from flowering canopy, increase leaf area – photosynthetic area) • Bring flowering forward to cooler conditions to extend the pod filling period • Manage fungal pathogens with agrochemical inputs • Address sulphur deficiency (atmospheric depositions have been decreased) • Maintaining rotational gaps: grow 1 year in 3 or more

  7. Conclusions for increasing OSR yields • Field yields of up to 5 t/ha have been achieved • 6.5 t/ha is not unrealistic ! • (Berry & Spink 2006) • Doubling yield in countries currently above EU average = extra 12,400,000 t (76% increase) without increasing land demand • Increase in yield is not at the expense of oil content

  8. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Francis Flénetand Alain Quinsac • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  9. Sunflower • Sunflower is mainly cultivated in Southern Europe: • Romania (900 000 ha in 2007) • Spain (613 000 ha) • Bulgaria (540 000 ha) • France (537 000 ha) • Hungary (470 000 ha) and • Italy (130 000 ha) • Strategies to increase seed yield: • increase the seed yield potential • decrease the effect of water stress, diseases and other limiting factors

  10. Increase the potential seed yield • Potential seed yield increased by 40 % from 1970 to 2000 in France, due to : • an increase in harvest index • a greater efficiency to intercept solar radiation per unit of leaf area • No obvious increase in seed oil content was observed • Further improvement is possible: • Biomass allocation, light interception through the canopy architecture, phenology

  11. Decrease the effect of limiting factors • Water stress • Increase the drought tolerance of varieties so that they adapt more efficiently to water availability • Increase the irrigation of sunflower • Convince farmers to follow recommendations (seeding, sowing density, sowing date etc) • Diseases • Resistance breeding, chemical application, cultural practices (no excessive N fertilization, wide row spacing, machinery movement along the different growing areas)

  12. Decrease the effect of limiting factors • Some weeds are not controlled by pre-plant or pre-emergence herbicides • Introduce herbicide-tolerant sunflowers to make possible a post-emergent weed control option • Insects (problem in Eastern Europe: Bulgaria, Hungary and Romania) • Chemical insecticides, alternative pest management strategies (rotating crops, altering planting dates, increasing natural enemies, sex pheromones…) • Slugs, birds and game animals: yield loss in France 0.3-0.4 t/ha • Seed treatments, sowing practices, better understanding of the biology of animals

  13. Conclusions for increasing the sunflower seed yield • The best combination of decisions must be taken to obtain high yields at low costs with little impact on environment. • Distribution of crops, machinery movement, crop rotation, variety choice, cultural practices and chemical applications • Breeding of new cultivars • Focus on seed yield potential, drought tolerance, resistance to diseases and insects

  14. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Francis Flénetand Alain Quinsac • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  15. Extraction Strategy Fermentation CO2 Densification Extraction Digestion Alkanes, wax esters, sterols and polycosanols Functional extracts

  16. Extraction Economic Factors • Overall extract yield (kg/kg raw material) • Typically 1-3% for straw/husk/leaf • Extraction column loading (bulk density kg/m3) • 650kg/m3 should be achievable by pelleting • Extraction time (kg CO2/kg raw material) • Typical extraction time: 2-3 h • Rapid load/unload mechanisms essential • Plant capacity

  17. Effect of Bulk Density

  18. Effect of Plant Scale Typical breakdown of operating costs for CO2 extraction Brunner,G., Supercritical fluids: technology and application to food processing. Journal of Food Engineering, 2005, 67, 21–33

  19. Conclusions for the potential chemical recovery from supercritical CO2 extraction • Densification and extraction technologies are commercially available and can be adapted to meet almost any biorefinery capacity. • Selective extraction of valuable chemical is possible but the yield will be low • Densification of raw material is essential • Economy of scale has been demonstrated with other raw materials • Continuous extraction could provide a quantum shift in costs

  20. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Francis Flénetand Alain Quinsac • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  21. Biomaterial Production • Huge potential resource • e.g. for sunflower: stem 25% DM, seeds 30% DM • European production of sunflower seeds in 2007: 5.6 Mt • Potential production of sunflower straw: 4.7 Mt/y • Today straw is used only as soil enrichment • Soy or rapeseed straws are not rigid enough to be harvested, BUT sunflower straws can be used (good fiber quality and high pectin content) • Sunflower stalk consists of the pith and the bark (husk), easily being separated through crushing

  22. Use of sunflower straw fiber • Pulping of sunflower straw • Suitable for cardboard • Suitable for particle boards if depithed or mixed with poplar wood particles • Rapeseed straws: few works on fiber characterisation

  23. Use of pith • Low density materials • No requirement for additives or mold-drying processes • Excellent mechanical properties are related to water (used in the forming process) • Insulating material • Pectin (food and cosmetic industry) • High anhydrogalacturonic acid content (77-85%) • Low acetyl content (2.3-2.6%) • Firm gels with Ca but sensitive to pH

  24. Aqueous extraction of sunflower oil • An interesting alternative to classical oil extraction • One stage twin screw extraction. • Solvent free • Seeds and fibers are added separately • The whole plant can be also used. • 70% extraction yield • The liquid phase is an emulsion stabilised by sunflower proteins (directly used in industrial applications or transformed to fatty acids and fatty esters) • The cake meal can be used to make biodegradable materials

  25. Thermo-molding of the cake meal • Suitable for: • Animal feed • Pellets for energy production • Thermo-molding (high temperature and pressure) application • Biodegradable and value-added agro-materials • Proteins are transformed and give mechanical resistance to the panels • Fibers ensure the structure of the panels

  26. Conclusions for biomaterial production • Stalks of sunflowers can be used to make cardboards or particle boards • Pith can be used for light density materials and for extracting the pectin • New aqueous oil extraction • Use of the whole plant • Fibrous cake meal can be used for new agro-materials

  27. Contents • Improving the production and yield of oil crops • oilseed rape (FERA, UK) • David Turley and Ruth Leybourne • sunflower (CETIOM, France) • Francis Flénetand Alain Quinsac • Utilization of by-products • Chemicals from supercritical CO2 extraction (UYork, UK) • Ray Marriot • Biomaterial production (INPT, France) • Antoine Rouilly and Carlos Vaca-Garcia • Methane production from residues (FORTH, Greece) • KaterinaStamatelatou, Georgia Antonopoulou and GerasimosLyberatos

  28. Methane production from residues • Anaerobic digestion is the breakdown of organic material by micro-organisms in the absence of oxygen. methanogenesis acidogenesis acetogenesis hydrolysis acetic acid volatile fatty acids alcohols CH4 CO2 biowaste monomers H2 CO2

  29. AD of Solid Waste

  30. Biogas utilization Biogas Desulphurisation Desulphurisation Gas treatment Gas treatment Reforming Compression Boiler CHP Fuel Cell Pressure Tank Heat Electricity Heat Electricity Heat Fuel

  31. AD of energy crops

  32. Residues - Characteristics • 1 m3 biogas yields • 5-7.5 kWh (total) energy • 1.5-3 kWh (electrical) energy

  33. Cost benefit analysis (on annual basis) • 1 m3 biogas yields • 5-7.5 kWh (total) energy • 1.5-3 kWh (electrical) energy • Investment: 2,000-5,000 €/kW • Operating: 2-4.5 € ct/kWhel • Electricity production value • 14.5 € ct/kWhel • Thermal energy value • 4 € ct/kWhheat • Fertilizer value

  34. Conclusion for methane production • Residues can be used for methane production • Profit is possible from: • Utilization of methane for electrical and thermal energy • Utilization of the digested waste as fertilizer • Methane production is profitable if the CHP unit operates on an annual basis. • Other feedstocks should be used in combination with rapeseed and sunflower residues to secure a continuous feeding (other agricultural wastes, manure etc.)

  35. Acknowledgements • Sustoil was funded under the 7th framework programme Thanks for attending 

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