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Commercial Success of ECLAIR Programme
AGRE-0061: The whole crop biorefinery project (Bioraf) |
AGRE-0061: The whole crop biorefinery project (Bioraf)
Science Background
Conventional processing of agro-industrial crops, such as wheat, tends to be on a large scale, aimed at a single product, produced from grain which has been selectively harvested, removed from the straw using a combine harvester. The whole crop harvesting concept consists of a series of integrated production lines that it was envisaged would produce synergistic benefits. The use of smaller facilities, situated close to the agricultural source should reduce transport distances, with only the more valuable products sent out of the area, rather than the movement of millions of tonnes of whole grain. In addition it was anticipated that fossil fuels would rise in price leading to a greater market for products for energy purposes and relatively cheap fibre products from the straw for non-food products, but that did not occur.
Objectives
The project was coordinated by the Bioraf Denmark Foundation, an international oriented non-profit research and development organisation, founded in 1988, with the purpose to support development of sustainable production systems based on renewable resources – biorefineries – in cooperation with universities, research institutes and industry. During the period of the ECLAIR project, Bioraf obtained 25% of its funding from industry, with the remaining funding coming equally from the EC and the Danish government. The main objective was to prove, at a sufficiently large scale, that the biorefinery concept is economically viable. The project encompassed selection of crops, intermediate storage and fractionation process for grains and whole crops.
Significant changes and results since end of ECLAIR
Bioraf Denmark has applied for one process protection patent and is planning a second.
Since the end of this project, Bioraf has targeted their research at production of tailored products for niche markets, from a controlled process from field to finished product.
In particular, they have concentrated on:
To this end they have established a processing/marketing link between agriculture and industry, and have developed and modified products in close cooperation with agriculture, the processing industry and end users.
The Biorefinery concept is considered promising by less developed regions and projects have been initiated in Greece, Spain, Poland and China. Bioraf Denmark aims to be an innovator, offering continuous services to these demonstration projects.
Research since the end of the original Bioraf project has concentrated on using a focused approach to obtain added value products. For example, gluten was an end product of wheat processing. This has been further refined to produce gluten fractions such as gluteins and gliadins.
Research into biorefining of oilseed rape, which was seen as unprofitable at the end of the ECLAIR project, has continued. Results in 1999 indicate that added value of more than 100% can be achieved by further refining oilseed rape to produce high value products such as bio-actives (antifungal, insecticidal, nematocidal, antitumour, chiral intermediates) and lipids (technical and edible oils).
At the same time, attempts have been made to interest the cosmetic industry in these proteins and to establish how much it is willing to pay for them.
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Added value of Bioraf biorefinery products from oilseed rape over traditional refinery products for ECLAIR Biorefinery (1995), 2nd Generation Biorefinery (1997/98) and 3rd Generation Biorefinery (1999) Left: Percentage by weight of refinery product for traditional refinery and biorefineries Below: Income from refinery products as a percentage of total income from traditional refining. |
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Results
At end of this ECLAIR project
Initial investigations identified suitable crops as wheat and rapeseed. Whole crop refining of wheat was not economically viable due to high storage costs (more than half of the total investments). However, a return on investment of between 20-25% could be envisaged if the crop was combine harvested and dry milled. Biorefining of oilseed rape resulted in an added value of only 14% over traditional refining. This would not cover the additional costs associated with biorefining and thus it was concluded that oilseed rape was not a commercially viable input into a biorefinery.
This project did not have a clear target and no money was available for pilot or demonstration plant. Thus the technical outcome was the identification of the products only. In general, results have required a reassessment of the concept, indicating that biorefineries cannot competitively produce bulk products, but should develop niche markets or act as a link between farmer and industry or consumer, producing tailor-made intermediate raw materials. The results were published in 1995 in 7 volumes (main report plus six background reports) as The whole crop biorefinery project. Copies are available on request from the coordinator.
Current position
The Bioraf Denmark project has received national (70%), European (20%) and industrial (10%) funding since the end of the ECLAIR project. However, they have been given an ultimatum by the Danish government – they must come up with results by the end of 1999. Their technical capabilities are valuable and the organisational concept has been transferred to other biorefineries plants.
By focusing on added value products and including farmers cooperatives and industry in the development (innovation) chain, it has been possible to demonstrate added values of more than 100% over traditional refining for oilseed rape. Similar approaches have been applied to wheat biorefining. However, the higher the added value due to further refining, the higher the processing costs.
Although promising possibilities exist, a commercial breakthrough for increased non-food use of farm crops is not imminent. This is due to the relatively low cost of raw materials based on fossil fuels and the well-developed and widespread use of production technology. However, consumer dissatisfaction with synthetic products is increasing in parallel with examples of products that were originally considered harmless but have subsequently been shown to have negative effects on health and/or the environment. These include organic solvents, asbestos, plasticisers and certain surfactants (particularly in cosmetics and healthcare products). This has led to a trend toward natural products based on biological raw materials. Many barriers to commercialization are non-technical and can usually be identified fairly easily by carrying out an economic evaluation. These include:
In order for this area of activity to grow, it is necessary to identify these obstacles. A better use of public money would be the funding of developments that overcome them. There is a requirement for simple tools (IT) that can be used to quantify these non-technical aspects. A clear objective should be identified with the emphasis on using existing knowledge from applied research to move products through pilot and demonstration research (such as that carried out at Bioraf plants) to industry in a focused way. This should take place in combination with activities that encourage industry to develop new products and markets. More emphasis should be given to results of research where basic research focuses on development of new products and markets. Farming cooperatives where farmers have an investment in the final product will enable them to benefit from the added value.
Impact
Commercial
This project has established that when attempting to produce a commercial product it is necessary to identify and take into account:
The Biorefinery concept has generated considerable interest in Europe and elsewhere. A feasibility study (funded under PHARE-P9312-08-02/320P) for Bioraf Polska completed in 1996 has led to a full-scale demonstration project. The Biorefinery Greece Non-Profit Foundation was established in 1995 as a 5 year project between Denmark and Greece. The intention is to establish technology transfer between the separate Northern and Southern innovation chains. The concept has also been adapted to local conditions and needs in China, where a demonstration plant coordinated by the Chinese Academy of Sciences is currently running. The Chinese are particularly interested in production of straw chipboard; thus Bioraf has established contacts with a UK strawboard manufacturer. Tekniker, Spain are investigating the use of the technology evolved for rapeseed to process olive oil. Bioraf Denmark acts as an innovator offering continuous services to these projects and will receive a fee if these projects fulfill their promise. Further income would come from training staff on Bioraf technology and ongoing sale and support of the concept.
Associated
Criticism of the original Bioraf project combined with experience gained has enabled them to focus their efforts more constructively. The original network is valuable, particularly now that they have identified what can be achieved by being more focused. Good relations have been maintained with Silsoe, UK and experience related to technical processes is exchanged. Bioraf Denmark are coordinating FAIR5-CT97-3778: Industrial applications of plant proteins as binders and co-binders in paper and paints and are involved in 2 other FAIR projects: FAIR2-CT96-1105: Cascade refining of European wheats for production of high quality products for the paper industry and FAIR1-CT95-0260: High quality oils, proteins and bioactive products for food and non-food purposes based on biorefining of cruciferous oilseed crops.
Further information
Kjøller, C. (1998) The biorefinery: a quality investment opportunity. In: Engineering Crop Plants for Industrial End Uses (Eds: P.R. Shewry, J.A. Napier & P.J. Davis), pp205-216, Portland Press, London, UK
Contacts
Author
Bioraf
IBMER
Nat Tech Uni Athens
University Vet & Agri Den
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by CPL Press:
03/07/2007
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