AGRE-0046 Vegetable Oil for Innovation in Chemical Industries VOICI

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Bulk Chemicals : ECLAIR Cluster I - Oils : Paints/Coatings/Plastics : Pharmaceuticals/Cosmetics : Plant Genetics : Process Engineering : Vegetable Oil/Fat

Crambe oilseed plants and end products, soap and lubricants.

SUMMARY

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. This project looked at the possibility of challenging this conventional approach combining whole-crop harvesting with a series of integrated production lines, which would (it was hoped) produce synergistic benefits. The use of smaller scale facilities, situated close to the agricultural source, would 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 as at present. Results indicate that a wheat-based biorefinery, based on traditional harvesting, could be profitable. However, enzymatic fractionation of rapeseed would not be profitable. In general results have required a reassessment of the concept, indicating that biorefineries cannot be competitive producing bulk products, but would have to develop niche markets or act as a link between farmer and industry or consumer, producing tailor made intermediate raw materials.

INTRODUCTION

This project looked at a number of novel crops which have been suggested as having potential as sources of various oils and fatty acids which could be used in the manufacture of products such as lubricants, films and resins. It evaluated agricultural, technical and economic aspects of three plants. These were crambe (Crambe spp), a member of the cruciferous crop which is closest to commercialisation in Europe; meadowfoam, (Limnathes spp), which has been grown as a crop in the USA and African daisy (Dimorphotheca sp), a wild plant originating from South Africa and Angola. In particular the project aimed to identify those aspects in the development of these new species which would be required to enable farmers to grow these economically. For an oil crop to be successful, the price of oil should be comparable with alternatives available to the user-industry. The oil must also be available in sufficient quantities and at the required technical quality and stability. Most current oil crops attract additional income from sale of the residues (meal) from oil extraction. The value of meal depends on the absence of antinutritional or other chemical residues which can damage animal health. Many, as yet uncultivated plants, contain compounds such as glycosinolates* which have to be removed by plant breeding techniques.

* Glycosinolates are any of over 100 related compounds which have deleterious effects on animals, interfering with thyroid function, adrenal glands, kidney and liver function. They are characterised by a thioglucose group, a sulphinated oxim and an organic side chain of an alkyl, aryl or indolyl group.

THE CROPS

Crambe can be grown as a spring sown crop in the temperate climate zone in many areas of Europe and both chemical and mechanical weed control are feasible. The target product is oil from the podded seed (one seed per pod). This oil is rich in erucic acid which is used in the production of poly-olefine films. It may also be used as a base for lubricants, etc. The meal by-product, which contains a high proportion of protein, could be used for animal feed. At present this is hampered by the presence of glucosinolates. Its main competitor is oil-seed rape, especially standard HEAR (High Erucic Acid Rape).

Meadowfoam can be grown in many areas of Europe, where it would have a short growing cycle. This, combined with the small size of the plant, make it susceptible to weeds. However, it was found that only a restricted number of herbicides could be used without harming the crop and no suitable herbicide could be found for control of broad-leaved weeds. The product is oil from the seed (each flower produces five one-seeded fruits). The meal is rich in protein, but again this contains glucosinolates. The oil contains unique long-chain fatty acids. Possible applications include use in cosmetics and lubricants.

African daisy has not been grown commercially as a field crop, but can be grown in many parts of Europe. This plant can produce dense stands in the field and weeds can be controlled by a variety of herbicides and also by mechanical means. Each flower produces many seeds in two distinct forms. These seeds contain oil rich in dimorphecolic acid, which has potential applications in lacquers and lubricants. They also contain sufficient protein for the meal might to be usable as animal feed. The main restriction to cultivation is the loss of seed before and during harvesting.

APPROACH

Each of the three potential crops were subject to field growth and breeding trials. The objective was to acquire knowledge of the agricultural cultivation of the crops and to produce seed for oil and meal studies. The composition of the seed was determined and the oil extracted, refined, distilled and analysed.

Yield distribution of 100 F3 lines obtained from the crossing of two parental lines (P1 and P2). The F3 distribution shows that Crambe abyssinica has a potential seed yield up to 4000kg/ha.

Main Results

Crambe The yield of crambe was about 2 tonnes/ha, or up to 3.25 tonnes/ha under favourable conditions. A 1992 demonstration project for farmers resulted in a two-year large-scale production on about 300 ha/year. Crambe oil works well in alkyd resins and improves humidity resistance and weatherability in car repair coatings. However, there is insufficient technical benefit to justify replacing presently used oils. In comparison with rape oil, friction and anti-wear charactaristics of crambe oil are similar and oxidative and thermal stability are superior.

Meadowfoam Yields by inexperienced farmers were 200-600 kg/ha although attainable yields are much higher. It was established that the oil contains more than 95% long chain fatty acids of which nearly two-thirds are eicosenoic acid.

African daisy Low seed yields of 500-2000 kg/ha were obtained. The oil could be extracted successfully using solvents or, preferably, super critical carbon dioxide extraction (SCE). The quality of oil extracted by SCE was good, appart from high pigmentation. Genetic improvement is needed (leaf properties, disease resistance, synchronisation of flowering, seed shattering and oil content).

COMMERCIALISATION

Crambe Existing equipment can be used for harvesting and oil can be recovered using conventional protocols. Although near to production, seed yield, pod density, disease resistance and glucosinolate content need further work. The oil is a new product in an existing market, competing mainly with rape oil. The raw product price is too high, although the valorisation of the by-products (straw and meal) might help in lowering the price of the oil.

Meadowfoam is unsuitable as an agricultural crop at present, due to low and unstable yields, weed problems and seed shattering at harvest. Breeding programmes are required to overcome these problems. As with crambe, the oil is a new product in an existing market.

African daisy A wild plant not yet ready for farmers, but with promising characteristics. The oil is a new product with possible speciality applications.

PARTICIPANTS

Institutions and industries working in areas of Agriculture (CPRO-DLO, AB-DLO, PAGV-DAT, CEBECO-Hanelsraad and VNK, The Netherlands) and Production - including Agro-Technology; Industrial Processing and Applications (ATO-DLO, Obertop BV and Unichema, The Netherlands; Gerdoc and Gatte Fossé, France; Blue Tec/FLS, Denmark; Fuchs Mineralölwerke GmbH and BASF, Lacke und Farben AG, Germany).