C R O P S T O I N D U S T R Y WP 3 Task Bio-based product Task leader: Przemysław Baraniecki,...

C R O P S T O I N D U S T R YC R O P S T O I N D U S T R Y

WP 3Task Bio-based product

Task leader: Przemysław Baraniecki,

Crops2IndustryCrops2Industry“Non-food Crops-to-Industry

schemes in EU27”


ContentContent

1. Objectives2. Progress of work3. Results 4. Status of deliverables & milestones5. Problems encountered 6. Plans for the next 6 Months


WP3 Bio-based products (INF&MP, CHIMAR, KEFI, NCPRI, ACCIONA, HEMPFLAX)

The main target of this WP 3 is to explore the potential and feasibility of the European industry to make high-value bio-based products from renewable agriculture and forestry feedstock and biotechnological routes.3.1. Oils,3.2. Fibers,3.3. Resins, 3.4.Pharmaceutical and other specialty products.


Ad. 1 Topics

WP 3 – Bio-based products

Task 3.1-3.4 (topics):1. Review on the product yielding capacity from various industrial crops

streams

2. Identify desirable quality characteristics that feedstock has to meet for mature industrial processes

3. The report on raw materials from non-food crops as alternative to fossil, petroleum-based and chemical resources

4. Set prospects to widen the range of potential feedstocks for the understudy industrial uses, based on the technology improvements

5. Identify restricting factors that inhibit broader industrial use of the biomass feedstocks (supply, costs, physical traits, consistency in quality, technical performance, research gaps, etc)

6. Set forth research gaps, prospects and recommendations to procure bio-based products will be tackled


Task 3.1 Oils (ITERG)

ITERG’s will report on bio-products:

• biofuels (oleaginous crops and oils for biodiesel production),

• biolubricants,

• biopolymers,

• paintings,

• fat and vegetable oils, and derived products users (food industry,

non-food industry and component manufacturers.


2. Progress of work

WP 3 – fibre flax – INF&MP proposition for all crops reports


Task 1. Review on the product yielding capacity from various industrial crops streams

The significance of the raw materials and bio-based products should be discussed and described on the base of current situation (vide questionnaires, which INF&MP is still

asking for, waiting for completing)


Flax (Linum Usitatissimum)

Diameter of elementary fibre: 15 – 22 [µm]:


The task 1 as well as all other tasks will be completed after obtaining the results derived from the entire set of the questionnaires, filled-in by the project partners. The tasks 5 and 6 should be compatible; the task 6 should be elaborated on the basis of profound analysis of the materials of task 5.


Non-deseeded raw straw Biomass for bio-fuel

Deseeded raw straw Sowing seedsRaw material for food and pharmaceutics production

Raw material for oil production

Retting sewage

Biogas

Fertilization

Pectine powder

Repeated rettings

Dew-retted straw Shives & dustBurning fuel

Wax production

Paper production

Fillers

Technical fiber Short fiber scutched tows

Short fiber matted tows

Special Carded yarn

Weaving Carded yarn

Technical fabrics

Bedlinen fabrics

Decorative fabrics

Ropes

Cottonized fiber

Nonwovens

Cotton wool

Paper prod.

Special Carded yarn

Weaving Carded yarn

Technical fabrics

Bedlinen fabrics

Decorative fabrics

Ropes

Long scutched fiber Special Carded yarn Cleaning material

Combing waste fiber

Carded yarn

Bedding materialInsulating matarial

Paper production

Felts

Threads

Technical and decorative fabrics

Nets and others Ropes

Long combed fiberSpecial combed yarn

Spinning waste material

Weaving carded yarn

Paper production

Bedding material

Nonwovens

Technical fabrics

Decorative fabrics

Tablecloths fabricsApparel fabrics

Underwear fabricsRopes

Fire hoses

Nets and other


Task 1. Review on the product yielding capacity from various industrial crops streams

Agriculture Raw Materials

Primary Industrial Raw Materials

Secondary Industrial Raw

Materials

Directions of use/Product example

Retted straw

Long scutched fiber Hydraulic sealing

Short fiber (tow) Nonwoven, insulation, Composite material, Pulp & paper

Carded yarn Technical fabricsDecorative fabrics, twine, ropes

Shive Particleboard,InsulationSolid biofuelConstruction material,Substrate for mushrooms,Composite Materials,Pulp & paper

Dust Compost, Briquettes


Task 2. Identify desirable quality characteristics that feedstock has to meet for mature industrial processes

2.1 Agricultural raw materials

Retted straw- average technical length – over 60 cm- content of properly retted stems – over 90%- straw colour – light grey, steel grey, silver grey- straw shape – at least 70% of normal, straight

stems- health condition – at least 80% of healthy stems- moisture content – utmost 16%- efficiency of long scutched fibre – at least 15%



2.2. Primary industrial raw materials

- fibre length – minimum 500 mm- fibre thinness – below 6.0 tex- fibre delicacy – delicate and soft fibre- greasy feel – very greasy felt fibre required- colour – homogeneous steel grey fibre- total loses in carding – maximum than 3%- breaking force – maximum than 14 daN.

Long scutched fibre



2.3 Secondary industrial raw materials

Shive

- moisture content – maximum 15%- fibre content – maximum 10%- the impurities content – maximum 15%- dust content – maximum 10%- content of required shive fraction – minimum 65%


Task 3. The report on raw materials from non-food crops as alternative to fossil, petroleum-based and chemical resources


Deseeded straw

- flax biomass as solid fuel (briquettes, pellets) substituting fossil fuels (coal, lignite)

- flax biomass as liquid fuel (second generation fuels) alternative to fossil liquid fuels (gasoline, diesel fuel)- additive of biomass in biogas reactors instead of fossil gas fuel (methane)- use in insulating mats instead of Styrofoam or mineral wool- replacement of man-made polymers based fillings in composites- use in production of low grade paper and elimination polymer based packaging



3.2 Primary industrial raw materials

- chemical fibres for spinning: PA, PE, PP, PAN, PET, PCV, PS, PW, glass fibre, carbon fibre, basalt fibre

- reinforcing fibres in composite materials manufactured by press moulding: glass fibre, carbon fibre, PE, PP, PET, PCV, etc.

- hydraulic sealing – synthetic sealing tapes

Long fibre




3.3.1 Shive

- particleboard bonded with natural bonding agents instead of particleboard bonded with synthetic bonding agents or particleboard based on polymers

- additive for construction material replacing mineral fillers such as expanded clay aggregates

- solid biofuel (briquettes and pellets) substituting fossil fuels (coal and lignite)- second generation fuels liquid fuel alternative to fossil liquid fuels (gasoline, diesel

fuel). Lignocellulosic raw material can be used for production of bioethanol by hydrolysis and fermentation. Process covers three stages: preliminary processing with phosphoric acid, enzymatic hydrolysis and fermentation.

- fillers to replace synthetic fillers in composite materials- pulp to replace polymeric packaging materials - agricultural and gardening substrates replacing mineral substrates


Task 4. Set prospects to widen the range of potential feedstock for the understudy industrial uses, based on the

technology improvements


4.1.1 Production of PHA (Polyhydroxyalkanoates) in statu nascendi by genetically engineered plants

Linseed crops are considered as good targets for seed-specific PHA production. Advantages of PHA synthesis in fibrous plants in order to modify properties of plant fibres are: - no need for extraction, - low amount of PHA can have significant impact on fibre properties. - synthesis of biodegradable plastics in the million ton scale while bacteria or yeast

produce material in the thousand ton scale. - when synthesized in plants to a level of 20-40% dry weight, PHA could become

competitive with the petroleum based plastics.


Task 4. Set prospects to widen the range of potential feedstock for the understudy industrial uses, based on the

technology improvements

4.2 Primary industrial raw materials

•Development of new generation of fibres such as:• biosilk,• fibres on base of polylactic acid, • poly- hydroxy- butyric acid (PHB) in statu nascendi,• fibroin, • natural nano-fibres, • and nano-fillers (like nanolignin from flax for UV blocking)


Task 5. Identify restricting factors that inhibit broader industrial use of the biomass feedstock (supply, costs, physical traits, consistency in quality, technical performance, research

gaps, etc.)5.1 Agricultural raw materials

Costs

• Due to high low weight/volume ratio costs of straw transport are very high, especially when long fibre production is involved

• Straw processing results in numerous by-products which become a waste that company needs to address – this generates costs. Some of them must be utilized on sight as their transport is not economically viable. This may generate additional costs, especially when no profitable use is possible.

• Alternatively utilization of by products needs bearing costs, especially when it is difficult or impossible to commercialize these by-products.

• Non-deseeded flax straw can be used as solid biofuel. However, low yield as compared to other crops used for energy production make it not viable economically

Retted straw



gaps, etc.)Agricultural raw materials

Physical traits• Due to high low weight/volume ratio costs of straw transport are very high, especially

when long fibre production is involved• Yield of straw is too low to use for energy purposes. • Biodeterioration, flammability limits the use of straw in some applications (whole

stem mats) resulting from elimination of applications where moist conditions prevail.

Consistency in quality• Straw is a preliminary raw material having high impact on use and quality of all

derivative products and by-products (fibres, yarns, fabrics, etc.), therefore its quality and quality is crucial. Quality faults have immediate impact on its application which usually is reflected in compromising the most premium uses.

Retted straw



gaps, etc.)Agricultural raw materials

Research gaps

• New, economically feasible fibre extraction methods are necessary that will eliminate weather dependency of retting process

• Cell and tissue structure of a plant is very complex and still many information is missing which has straight impact on efficiency of fibre extraction technology (e.g. on efficiency of enzymes)

Retted straw


Task 6. Set forth research gaps, prospects and recommendations to procure bio-based products will be tackled

6.1. Agricultural raw materials

Basic research• genetic and agronomic studies to enhance economic value of flax yield • testing insulating properties (acoustic, thermal) and energetic value of flax straw

Applied research•improvement of biomass/biofuel, pulp & paper, whole stem mats production technology from deseeded straw

Prospects and recommendations•intensify legislation necessary to increase the share of renewable raw materials in energy feedstock of EU•promotion financial mechanisms to use flax straw for biomass/biofuel, pulp & paper, whole stem mats production. Such mechanisms are necessary to improve price competitiveness of these products and replace traditional goods based on fossil raw materials•deseeded flax straw from seed plantations and plantations yielding poor fibre quality can be used for fuel.

Deseeded straw



6.1.Primary industrial raw materials

Fibre Basic research• genetic and agronomic studies to enhance economic value of flax yield • testing insulating properties (acoustic, thermal) and energetic value of flax straw

Applied research• improvement of biomass/biofuel, pulp & paper, whole stem mats production technology

from deseeded straw

Prospects and recommendations• intensify legislation necessary to increase the share of renewable raw materials in

energy feedstock of EU• promotion financial mechanisms to use flax straw for biomass/biofuel, pulp & paper,

whole stem mats production. Such mechanisms are necessary to improve price competitiveness of these products and replace traditional goods based on fossil raw materials

• deseeded flax straw from seed plantations and plantations yielding poor fibre quality can be used for fuel.




Noils

Basic research• flax noils usefulness evaluation for production of new bioproducts

from the group of worsted carded yarn, garments, table cloth, bedlinen, decorative fabricsApplied research• manufacture technology development for production of fertilizers

and fuelProspects and recommendations• wider use of noils for production of worsted carded yarn, garments, table cloth, bedlinen, decorative fabrics requires improvement of products manufacture technology and their competent promotion (education, PR, advertisement)



Product examples

Medicinal use

Basic research• intensification of research on flax fibre use for production of wound dressings and band-aids• research on lignan effect on cancer cells spread limitation in human body

Prospects and recommendations• production of wound dressings and band-aids with better healing

properties resulting in quicker wound healing• production of medicaments used in cancer treatment


3. Results

• "Flax template" prepared for tasks 3.1-3.4• Questionaires prepared and sent to WP3 partners to collect additional data• Paritiall drafts prepared on some other tasks in WP 3 (medicinal plants, resins)


4. Status of deliverables & milestones

Delivery No.

Scope Responsible partner Delivery date Status

D 3.1 – D3.4

Oils*

Fibres*

Resins*

Pharmacls*

ITERG

KEFI, INFMP

CHIMAR

NCPRI

M 15, M 30

M 15, M 30

M 15, M 30

M 15, M 30

On track

On track

On track

On track*…that can be produced by the European bio-industry

Milestones: M13-M16 Compilation of information on… M12 (M14, M15&M16 on track)


5. Difficulties encountered

Cooperation between WP3 Leader and WP3 Partners:

• Questionaires feedback not satisfactory• Poor information on advancement of work in WP3 (except

Task 3.3; 3.4)• Objective obstacles – many information necessary for WP 3

tasks are confidential, inclomplete or difficult to obtain


Plans for WP 3 for the next 6 months

Description of work10.11.2010

30.01.2011

31.03.2011

31.04.2011

30.05.2011

Final version of WP 3 for Fibre flax,

Questionaire results for 3.1-3.4

Draft report on 2 selected plants in all tasks (Task 3.1-3.4) WP3 (eg. Task 3.2 – flax, hemp)

Final report on 2 selected plants in all tasks (Task 3.1-3.4) WP3 (eg. Task 3.2 – flax, hemp)

Draft report on 2 selected plants (Task 3.1-3.4) WP3 (np. Task 3.2 – kenaf, nettle)

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C R O P S T O I N D U S T R Y WP 3 Task Bio-based product Task leader: Przemysław Baraniecki,...

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