SUMO project Laymans Report

ELAC2014/BEE-0364

Sustainable use of biomass from oleaginous processing w w w. s u m o - p r o j e c t . e s CONSORTIUM

Background Rapeseed global production was around 58.4 million tons in the 2010-2011 season. Rapeseed is primarily cultivated for animal feed, owing to its very high lipid and average protein content. World production is grown rapidly. In the EU the main producer is France, followed

by Germany with more than 4,8 Million Tonnes. Rapeseed oil production is also important in the EU (around 10 Million tonnes, with and emerging production in South America, especially in countries like Chile (62,000 tonnes).

Olive oil world production is around 3,4 Millions tons. Production in the EU accounts for the 77% of the world production. Olive oil sector in the EU represents 1,75% of the Final Agricultural Production. Spain is the world leader with a production around 1,4 M tonnes (42% of the total production in the EU), with more than 2 Million Hectares of cultivated land and 500,000 jobs. Portugal produces more than 450,000 tonnes and Argentina has become the first producer in South America with 17,000 tonnes of olive oil (the 10th in the world ranking). In Uruguay, the olive oil industry has grown in the last ten years becoming into the most planted fruit specie, reaching actually almost 10,000 hectares with up to

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1,500 of direct employment and 2,500 during harvest time. From 2005 to 2010, the number of hectares in Chile under olive cultivation has increased by 45%, with especially large increases in the last two years. There are currently around 24,000 hectares under production, and is projected to have 29,000 hectares under production by 2015.

Regarding the technology used, the rapeseed oil production process is very similar in all countries. On the contrary, in the case of olive oil production, three methods are currently used

(traditional system, continuous 2-phase extraction system, and continuous 3-phase extraction system) although the 2-phase extraction system seems to be the most widely adopted in all countries of the SUMO project.

In the case of olive oil production, the most important by-products are olive mill waste water, olve oil press cake or olive pomace (OP) and olive marc (OM). In the main producing Regions, olive pomace is sold to companies named orujeras for a secondary extraction to produce orujo oil sold for human consumption and olive marc (orujillo), which is dried and used in co-generation facilities for producing energy. The amount of olive pomace used with this aim is increasing; however, there is a percentage, around 40%, that is yet not further processed in this way. Moreover, this is a practice that is not generally introduced in all producing countries, where the olive pomace is mostly composted or directly thrown in the olive cultivars.

feed after soybean meal. On the other hand, the press cakes are the most important byproducts of decentralized oil mills; in contrast to the extraction meal, the rapeseed cakes are not oil-free, but contain still up to 18 % crude fat. The rapeseed cake is highly demanded in countries with an important animal production like Spain and France due its high nutritional value. Overall, 5.2 million tonnes of oil cake and oilmeals arised as by-products of rapeseed oil production only in Germany.

In the case of rapeseed oil production, the most accumulating by-product is rapeseed meal which is used especially in the feeding of cattle and pigs and in countries like Germany, is the second most important protein source for

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Project objectives The aim of the SUMO project, Sustainable Use of bioMass from Oleaginous processing, is to develop different but complementary valorisation routes for the sustainable use of the main oily seeds processing by-products.

The general obtained result is the design of several alternatives of bio-refinery units adaptable to the current biomass processing and consumption sites in the participating Countries, where the oil seed processing sector is very important. The alternatives intend to be enough flexible to process vegetable processing by-products and finding synergies with other complementary wastes generated in the nearby. The valorisation routes to be developed comprise the use of the biomass and its components in human consumption, feed, biofuels and energy.

To achieve these objectives, the consortium has made an inventory and diagnostic of the current situation regarding the management of the by-products generated by the oilseed processing. Then they have developed one case study by participating Region and proposed a biorefinery scheme for “in situ� treatment of lignocellulosic wastes that could be extrapo-

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lated to other similar byproducts and regions.

At least 6 different products have been envisaged to be produced from the selected waste streams and the respective feasibility studies for the proposed solutions as result of the international collaboration.

Activities The goals of the SUMO project have been achieved through the development of following activities: 1. Diagnostic and inventory: detailed inventory and characterization of the by-products from rapeseed and olive oil production, the description of the current situation in the partner countries, the management types, existing valorization routes, regional initiatives, legislative aspects and the identification of stakeholders for innovative valorization opportunities.

2. Development of valorization approaches, as well as the characterization the obtained products, in order to obtain valuable information about the technical feasibility of the proposed bio-refinery processes. This information will be used as a base for the further definition of the Case Studies in each of the regions and the economic and environmental assessments. The assayed technologies are following:

• • • • • • • •

tation Dephenolization + anaerobic digestion Pyrolysis Gasification Composting Innovative dehydration technology Densification for combustion Pelletization in feed formulation Residual lipid supercritical CO2 extraction

3. D efinition of valorization proposals and feasibility studies for each studied Region (case studies): legal, economic and environmental feasibility of the proposals; the definition of the conditions for the implementation of the valorization protocols and possibilities of extrapolation to other production sites.

4. Communication and dissemination activities: sectorial workshops, project newsletters, publications and ellaboration of an exploitation plan for the project results.

• Microalgae biomass production in liquid phase of olive oil press cake • Acetone-Butanol-Ethanol (ABE) fermen-

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Proposed technologies / Approach The project has developed different ad hoc solutions adapted to the current situation and needs of the local industries and markets, that could be integrated following the bio-refinery concept giving priority to the more valuable options. Different products have been obtained from a same waste stream: the by-products from olive and rape seed oil production.

Each partner has developed a Case Study, a practical example of the potential application

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of the technologies developed during the project in a scenario representative of their Country. Each of 6 case studies presents an analysis of the economic, legal, and environmental feasibility of the most promising of the proposed technologies; the definition of the conditions for the implementation of the valorization protocols and the possibilities of extrapolation to other production sites or scenarios.

10 Different valorization processes developed and their corresponding feasibility analysis (legal, economic and environmental): • Microalgae biomass production in liquid phase of olive oil press cake • ABE fermentation of carbohydrates extracted from microalgae • Dephenolization + anaerobic digestion of olive oil press cake & olive marc • Pyrolysis of olive oil press cake • Gasification of olive oil press cake • Composting of olive oil press cake • Innovative dehydration technology of olive oil press cake • Densification for combustion of olive oil press cake • Use in feed formulation of olive oil press cake and rapeseed exhausted extraction meal • Residual lipid supercritical CO2 extraction (rapeseed extraction meal, olive marc & microalgae)

10 Product prototypes obtained from the processing of the studied by-products: • Olive polyphenolic extract • Microalgae biomass • Rapeseed cake, microalgae and olive pomace lypophylic extracts • Feed formulation • Biogas (methane) • Biobuthanol • Syngas • Biochar • Briquettes for combustion • Compost

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Exploitable results Polyphenols removal resulted in quite significant enhancement in the biodegradability of OP and OM as well as biogas and methane production. Olive polyphenols could be an additional income source for secondary olive oil extractors (orujeras) or for first extractors (almazaras) where orujeras do not exist. In the current case study model, the biogas plant would generate very little income in the case of Spain although the economic feasibility in each of the regions should be assessed according to their specific renewable energies policies.

The experimental results showed that it is possible to convert the liquid fraction of alperujo, as culture medium for microalgae cultivation under the developed protocol. Microalgae biomass can be fractionated to obtain a soluble sugar rich fraction that was used as substrate for ABE fermentation to produce biofuel. The remaining biomass was further processed to obtain lipids and proteins. The effluent after the microalgae cultivation was recommended for irrigation on the same olive field. Therefore, it is important that local regulations allow using the effluent for this purpose.

OP and OM are possible by-products to be used as a combustible for gasifiers, with the

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objective to produce energy and to increase the balance of energy of the producers. Results of gasification experiments proved that OM gasification is more efficient that OP gasification. The only pre-treatment needed for the gasification is the densification. The goal of this technology is the energetic independency of the company but, again, its profitability depends on the possibility of selling the energy surplus.

Two solid waste management protocols were developed for the olive industry: one for composting and the other for pyrolysis. The production of an organic fertilizer to improve the soils of olive establishments was achieved, useful in regions where the soil quality needs some corrective enrichment.

OP has shown also its potential as component in feed formulation mixed with other available cultivars like alfalfa and carob, in regions where the demand on feed is high, the animal exploitations are atomized and the access to feed producers is difficult.

The products of high-pressure CO2-extraction, supplementary aqueous-ethanolic extractions, as well as rapeseed cake (RC), OP, OM and microalgae Chlorella protothecoides products

have been chemically and microbiologically tested and evaluated for their suitability to be used as a cosmetic or feed raw material.

Degreasing makes the press cakes easier to digest and can be used in larger dosages than the fat-rich press cakes. The protein-rich rapeseed and algae co-products of the oil extraction can be a good protein source for all farm and pet species. The fiber-rich olive residues could be used for rabbits and other rodents or used in small doses as a filler. The degreased ex-

traction residues can be used as a component in tilapia feed formulation, with the rapeseed residues being particularly valuable because of their high protein contents.

As a main deliverable, the partners of SUMO have ellaborated an Exploitation Plan for the obtained results, valorization protocols or procedures and products thereof obtained.

The following figure gives an overview of the processes assayed in SUMO, their products and corresponding yields.

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Impact Sectorial Workshops 6 dissemination sectorial workshops organised at national level: • 9-10 March 2017. Ölmüllertage in Straubing im Kompetenzzentrum für Nachwachsende Rohstoffe. Straubing (Germany). Organized by ILU (http://www. regineering.com/daten/Oelmuellertage_2017.pdf)

• 20 October 2017. Talca (Chile). Organized

by CEAP • 23 October 2017. San Juan (Argentina).

Organized by INTI • 25 October 2017. Jornada de Olivos. Las Brujas (Uruguay). Organized by INIA • 23 November 2017. Guimaraes (Portugal).

Organized by CVR

• 12 May 2017. EXPOLIVA. Jaen (Spain). Organized by AZTI (http://www.expoliva.com/)

More information about the project, events and related published material can be found in: http://www.sumo-project.eu/en

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Publications, Congresses: Type

Responsible

Title

Date

Place

Public

Scope

ILU

FoodBerlin - Science for Sustain14-nov-16 able, Healthy and Safe Food

Humboldt-Universität Berlin

Scientific ComInternational munity

ILU

Participation in the EU High Level Panel and the Co-operation Exchange

19-21 January 2017

The international “Global Forum for Food and Agriculture”; Berlin, 19-21 January 2017

Scientific Community, IndusInternational trial, Social society, Media

ILU

Session - Plant-based Oils: “Sustainable Use of Biomass from Oleaginous processing (SUMO)”, Author: M. Sandmann

10-may-17

Bioeconomy Conference; Halle

Scientific ComGermany munity

AZTI

2C - Bioenergy - “New integrated polyphenols recovery and anaerobic digestion of two-phase 07-jun-17 olive pomace (alpeorujo)”; Author: Mikel Orive

Renewable Resources and Biorefineries RRB-13; Wroclaw (Poland)

Scientific ComInternational munity

Meeting/ Workshop

CEAP

Meeting to present SUMO project: “Valorización de residuos y gestión de la cosecha en la industria olivícola” (Waste valorization and crop management in the olive industry).

01-sep-16

CEAP facilities, Talca

Regional olive oil producers and national organization of producers

Oral presentation

CVR

SUMO: Objectives, milestones and current stage of development

23-sep-16

CVR’s facilities: Value Scientific ComPortugal project Portugal munity launching event

CEAP

Demonstration of hydroxytyrosol extraction and microalgae 22-nov-16 production from wet olive pomace “alperujo”.

Conference

Conference

Conference

Conference

Demonstration event

Other scientific papers and technical articles are in press or in preparation.

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CEAP facilities, Talca

Industrial, Governmental institutions

Chile

Chile

Partners

PROJECT COORDINATOR. AZTI (www.azti.es) has over 30 years’ experience and international presence in over 45 countries, boasts a team of over 240 experts, aimed at shaping ideas that, once transformed into products and services, generate business initiatives and recover and preserve natural resources.

It carries out strategic and applied research in an international context, providing comprehensive and innovative solutions for its clients in marine and food innovation. Transforming science into value and wealth for the society of today and tomorrow is the hallmark of AZTI.

ILU Institut für Lebensmittel- und Umweltforschung e.V. is working as a public, non-profit, independent, industrial-related research institute with focus on applied research, analytics and training/education in the fields of, food/feed technology, analytics and microalgae biotechnology. ILU is a leading Research Institute and Tech- and Knowledge Transfer in the field of oily crops and legume based food technology. We are main actors for technological and analytical support of applied research in the fields of food, feed, biotechnology and knowledge transfer, analytics and environmental protection.

ILU possesses an excellent basis for technological trials in extraction, milling, grinding, fractionation, extrusion, hydrothermal treatment, food, feed and cosmetics production.

INIA is a public nongovernmental organization dedicated to research and development of the agricultural sector. With five research stations in the country and more than 500 staff members INIA is the main institution researching the food chains with more than 25 years since its foundation and 100 years of experience inherited from the official “Centro de Investigaciones Agropecuarias Alberto Boerger”. The priority given to applied research and innovation gives close contact with the primary sector and the industrial processes, looking for increased sustainability, competitiveness and products with added value.

El Centro de estudios de alimentos procesados de la región del Maule, Chile, CEAP (www.ceap.cl) is a private nonprofit corporation, initiative developed in conjunction with the Regional Government of Maule and led by the following research institutions in the region: INIA, University of Talca, Catholic University of Maule, and two major agribusiness: SURFRUT LTDA. and Sugal Chile. Its main objective is to add value to products and processes of horticultural agribusiness Maule Region.

The CVR is a non-profit organization that has been created in 2002, from the initiative of University of Minho, the Industrial Chamber of Minho, the Portuguese Foundry Association and TecMinho - technology transfer center of the region of Minho, accounting with around 70 private companies as associates.

INTI National Institute of Industrial Technology is a public institution of Argentina (http://www.inti.gob.ar/inglesrwd/). It is the research institute and industry-related development in various fields, focusing on applied research, analysis and training in the field of food technology, chemistry, plastics, materials, etc. It has a broad experience in development and transfer to industry. In particular, in the case of the work of the institution in the region of Cuyo (olive region) in Argentina, INTI observed a need to provide value in origin and use residues.

This Project is supported by ERANet-LAC 1st joint call.

Ref. ELAC2014/BEE-0364 http://www.eranet-lac.eu/