Biowaste 4 SP

Senior Scientist Ph.D. Anne-Belinda Bjerre

Biowaste for SP new EU project with partners from EU, Africa and Malaysia

Program for Food, Agriculture and Fisheries, and Biotechnology

Proposal full title:

Processing of biowaste for sustainable products in developing countries

Biowaste4SP

Proposal acronym:

Type of funding scheme:

Specific International Cooperation Actions (SICA)

KBBE.2012.3.4-01: Conversion of biowaste in

Work Progr. topics addressed: developing countries

Name of the coordinating person: Dr. Anne-Belinda Bjerre Danish Technological Institute (DTI), Denmark ANBJ@dti.dk

Partners in Biowaste4SP
Participant nr. 1 2 3 4 5 Participant organization name

Danish Technological Institute Swedish Environmental Research Institute TBTAK Marmara Research Center SIRIM Berhad Council for Scientific and Industrial Research Institute of Industrial Research (CSIR-IIR)
Council for Scientific and Industrial Research Agricultural Research Centre University of Siena Hassan II Institute of Agronomy and Veterinary Medicine Danish Technical University Ethekwini Municipality Myagri Group of Companies BioVelop AB Moroccan Association for Solid Waste African Institute for Capacity Development World Association of Industrial and Technological research Organizations

Participant Short name DTI IVL TUBITAK SIRIM CSIR-GH

Org Type

Country

Research Research Research Research Research

Denmark Sweden Turkey Malaysia Ghana

6 7 8 9 10 11 12 13 14 15 16

CSIR-ZA ARC UNISI IAV DTU ETM MYAGRI BV AMADES AICAD WAITRO

Research Research University Research University Public SME SME NGO Research NGO

South Africa Egypt Italy Morocco Denmark South Africa Malaysia Sweden Morocco Kenya Malaysia

About Africa

Africa is the world's second largest continent, and one of the worlds fastest growing markets. Africa is the world's second-largest and second mostpopulous continent, after Asia:

30.2 million km (11.7 million sq meters) including adjacent islands Africa covers about 5% of the Earth's total surface area and 20% of the total land area. Africa accounts for almost 15% of the World's human population:

With almost a billion people led by Nigeria (135mil), Egypt (80mil), Ethiopia (76mil), Congo-Kinshasa (65mil) and South Africa (44mil). There are an estimated 2,000 languages spoken across the continent.

African agriculture accounts for about 30-40 percent of Africas GNP.

Africa accounted for only 2 percent of world fertilizer consumption in 2003/04. Total fertilizer nutrient consumption in Africa increased with 4.3 percent. Nitrogen consumption increased with 3 percent and phosphate and potash consumption increased with 5.6 and 6 percent respectively. Although Africa comprises 58 countries, fertilizer consumption continues to be mainly restricted to 10 countries and nitrogen and phosphate fertilizer production capacity exists in only 8 countries. The main consumers in the region are Egypt, South Africa and Morocco. Total fertilizer consumption in sub-Saharan African countries remains at approximately one percent of World fertilizer consumption.

Replacement of fossil fuel with biomass

& Fertilizer Clark & Deswarte 2008

A step forward to fulfill this goal is..

to replace fossil fuel with renewable fuels and energy to replace fossil chemicals with biomass based chemicals and materials

The biorefinery

Biorefinery of African biowaste feedstocks

Definition of biorefinery:

Integrated and combined processes for the conversion of biomass into a variety of food, feed, chemicals, biomaterials, and energy at the same time maximising the value of the biomass and minimising the waste

Fertilizer

Cost is the critical challenge for success.

Thus, easily accessible and low cost biomass feedstock is a prerequisite for making biobased production economically feasible. Industrial, agriculture and municipal biowastes have the potential to be that resource. However, it is of great importance to be aware of how to utilise the different sources of biowaste and for which purpose.

Knowledge about biowaste composition is crucial

In order to do this in the best possible way, one has to know about chemical composition: 1) i.e. the biowaste contents of carbohydrates, both starchy and lignocellulosic based should be considered and evaluated as potential (and best) fermentation substrates for bioenergy carriers, chemicals, and food/feed ingredient (e.g. amino acids). 2) i.e. the biowaste ash contents, which are potential plant nutrients as in fertilizer. 3) and biowaste proteins, which are important ingredients in food and feed applications as well as fertilizer.

Objectives of Biowaste4SP

The objective of the proposed project is to show and demonstrate the technical roadmap - a strategy - for efficient technological utilisation of selected significant biowaste in five African countries - Morocco, Egypt, Ghana, South Africa, and Kenya- derived from both the industrial and agricultural sector, thus, turning biowaste into a new resource for sustainable products.

WP1:. Sugar based raw materials: agriculture and food industrial waste

Bioethanol, Lactic acid, Protein, Amino Acids

WP2. Nutrient rich raw materials: agriculture waste and manure

Biogas WP3: Sugar platform Pretreatment and enzymatic conversion WP4: Bioconversion Fermentation by SSF, SHF and solids state WP5: Biogas production

WP6: Compositing (DEMO)

WP7: Sustainability assesment and LCA

WP8: Knowledge transfer, training and dissemination

Incl. Specialty microorganisms production

WP9: Project management

Biofertilizer

Process diagram and WP interactions of Biowaste 4 SP: Blue lines: Orange lines: Green lines: Primary process flow Main product(s) Waste streams

Biowaste 4SP flowdiagram

Examples of biowaste ressources in Africa

Sugars based biowaste (industrial food waste)

Banana (whole fruit) biowaste Sweet potato biowaste Cassava (Manioc) biowaste Coffee biowaste Rice bran Rice straw

Nutrient based biowaste

Municipal solid waste Manure Rice straw Cassava leaves

Production of chosen significant agricultural products in Egypt, Morocco, Kenya, Ghana, and South Africa.
Annual Production (metric tons)
Bananas Cassava (2) Olives (2) 500 000 770 000

Egypt

Morocco

Kenya

Ghana

South Africa

1 100 000

843 465 819 967 12 230 600

373 637

Sorghum (2)
Rice, Paddy (2) Sun flower seeds (2) Cotton (bales) (1)

880 000
7 500 000

350 550
391 440 801 000

1 000 000

1 000

20 000

70 000

Source: 1) FAO, FOOD AND AGRICULTURE ORGANIZATION OF THE UNITED NATIONS, 2009; http://faostat.fao.org/site/339/default.aspx; 2) http://www.nationmaster.com

Biowaste 4 Sustainable Products in Africa

Target products: Feed and food (protein and amino acids) Energy (biogas and bioethanol) Fertilizer (biofertilizer) Value-added products (lactic acid and health care products)

Potential biowaste resources and potential products from the conversion of these
Biowaste Cassava Cassava leaves Banana Rice hulls Rice straw Cotton stock Olive waste Sun flower waste Soya waste Manure Sewage sludge Sugar rich + + + + + Nutrient rich + + + + + + + + Protein rich + Potential product ET, LA, AA, DDGS, PRO FZ, BG ET, LA, AA, DDGS ET, LA, AA, DDGS, VA BG, FZ BG, FZ BG, FZ BG, FZ BG, FZ BG, FZ BG, FZ

+ +

+ +

(Key to abbreviations: ET_ ethanol ; LA_ Lactic acid; AA_ amino acids; PRO_ proteins; VA_ value added products ; BG_bio gas; FZ_ Fertilizer; DDGS_ Distillers dry grain solids; in this context the solid rest after fermentation )

What kind of feedstocks are needed ?

Feed Sugar based feedstocks

Energy

Nutrient based feedstocks

Fertilizer

In our project we will do process integration:

Sugar based feedstocks

Nutrient based feedstocks

Feed

Energy

Fertilizer

Value added products

Development of whole crop biowaste biorefinery

Starch

Biowaste (banana, cassava etc)

Food Feed Biofuel Fertilizer

Lignocellulose

Banana: a sugars based Biowaste ressources in Africa, an example

Composition of banana
Starch based material

Lignocellosic based material

Banana amylopectin (starch) and cellulose (lignocellulose) both sugar polymers

Cellulose

Starch material amlylose/amylopectin

Plant cell walls contain C5 and C6 sugars and lignin

Cellulose

Hemicellulose

Wheat straw in Denmark

Lignin

Sugar platform from starch (1. generation) and from lignocellulose (2. generation) for bioethanol production
1. generation sugar platform:
2. generation sugarplatform:

Substrate:

Sugar (sucrose) from sugarcane and starch from maize or wheat.

Milling

Substrate:

and cooking (atmopheric pressure) before enzymatic hydrolysis.

Optimised,

Lignocellulosic materials (straw, corn stover, wood, waste) Chemical/physical pretreatment at high pressure and temperature necessary to facilitate enzymatic hydrolysis.
More

cheap commercial enzymes available

enzymes that are still improving

expensive, but now commercial

Starch and cellulose both made of glucose

amylose consists of glucose bound by alfa-1-4 linkages

Cellulose consists of glucose bound by beta-1-4 linkages

Development of whole crop biorefinery

Starch

Banana (example!)

Food Feed Biofuel Fertilizer Value-added

Lignocellulose

Feed and food (protein and molasses) as byproducts from bioethanol production

1st generation starch bioethanol

Fuel ethanol (main product)

Corn Kernels

Starch Conversion

Sugar

Yeast Fermentation

Distillation

DDGS (fodder)

1st generation starch bioethanol, DDGS and amino acid production from biowaste in Africa

+ a protein containing biowaste ressource

1 Enzymes 2
Pretreated banana starch + hemicellulose
Sugar conversion C6-C5 Monomer sugar Fermentation Precipitation Purification or destillation

Bioethanol (main product)

Lactic acid (main product)

SSF

3
Amino acids

DDGS (fodder)

Value added-products

Value-added product from rice bran

Chemical composition of rice bran

Rice bran:

Starch:
Fiber: Protein:

up to 45%
17-20% 14-16%

Oil /fat:
Ash:

4-5%
4%

Moisture:

12-13%

Example: Rice processing

Conventional / Short Roller-Milling

Bran
20-35%

Flour
65-80%

Proteins, Fibre,Gluten, starch oils, soluble fibre

MD, Glucose

Product Fraction overview

Main products Especially for prebiotic content
0
Notes: 1. A (*) after the product number means that it is an intermediate product only. 2. A (**) after the product means that it can be sold as is or processed further. 3. All % figures relate to the cereal bran.

Wheat Bran
6** 6.5* Insoluble Fraction: 55-60%

0.5* Soluble fraction (intermediate): 40-45%

Intermediate

7 XyloOligosaccharide :10-20%

9** 8 Soluble Xylans, Aleurone-rich prebiotics: 10-20% Protein 3-4%

10 Insoluble Dietary Fibre: 18-25% Aleurone Rich Protein, Hydrol.: 3-4%

1 Glucose Syrup 15-25%

2** Germ Rich Protein 7-15% 2.5

3 Xylan rich protein 7-15% GRP Hydrolyzed 7-15%

9.5

11 Aleurone-rich Oil: 0,5%

12** Defatted Aleuronerich Protein: 3-4%

12.5

4 Germ Oil 1,5-3%

5.5

5** Defatted Germ Rich Protein 6-12%

DARP, Hydrolyzed 3-4%

DGRP, hydrolyzed 6-12%%

Lactic acid from the rice bran starch

Process diagram, lactic acid production

Rice bran

Wet milling

Separation

Glucose syrup

SSF by lacto bacillus

Lactic acid solution

Fibres

Precipitation and purification

Lactic acid

Fertilizer as by-product from biogas production

Biofuel : Biogas (byproduct) and Fertilizer (main product)

All lignocellulosic biowaste streams will be mixed with municipal solid waste (and/or) manure and treated in a biogas plant

Biogas

Fertilizer

Biogas plants are multifunctional plants

Production of Renewable Energy biogas (CH4 ) Reduction of greenhouse gasses emission of CH4 and N2O Recirculation of nutrients from organic waste products Optimized distribution of nutrients from manure and organic waste

Agriculture

Biogas

Environment

Energy

What happens in the biogas plant?

Organic material is degraded Nutrients are mineralized Pathogenes and weed seeds are destroyed

Biofertilizer

Composition (aim to be obtained during the project)

Renewable and fossil free Organic rich solid fertilizer Fully loaded with all 14 essential plant nutrients

Pelletized or compressed to reduce transport costs and facilitate storage

Biofertilizer produced in a biogas reactor

Lignocellulosic residues (Sugar for biogas and lignin for fertilizer) Biogas Manure/municpal solid waste (nutrients N,P,K for fertilizer and more sugars for biogas) Fertilizer (liquid and solid)

Fertilizer finally made by composting of solids from biogas reactor (video from Malaysia)
Composting of biomass : 2 times a day oxygen addition by forced air ventilation