EIP-AGRI Workshop ‘Building new biomass supply chains for the bio-based economy’ May 27 – 28, 2015 – Alghero, Italy
EIP-AGRI Workshop ‘Building new biomass supply chains for the bio-based economy’May 27 – 28, 2015 – Alghero, Italy
Catia Bastioli, CEO of Novamont S.p.A. and Matrìca S.p.A.
A concrete example of fully integrated biorefinery in Italy
INDUSTRY
R&D
HUMAN CAPITAL
1996 - RESEARCH CENTRE →2014 - TURNOVER OF 145 MIO/€257 PEOPLE DIRECTLY EMPLOYED
BY NOVAMONT(2014) 500 PEOPLE EMPLOYED
INCLUDING JVs AND START-UPs)
25-YEAR R&D EXPERIENCE6.2% OF TURNOVER20% OF EMPLOYEES 1.000 PATENTS
MORE THAN 250 TRAINING PROGRAMMES SINCE 2000
Novamont todayA knowledge-based industry
DEVELOPMENTMODEL OF INTEGRATED BIOREFINERY
Biorefinery integrated in the local area: primarily dedicated to the production of chemicals and high added-value
products different local raw materials (low-input crops, scraps, etc.) – respect for
local biodiversity use of marginal lands and re-industrialization of deindustrialized sites integration of a wide and rising range of low-impact technologies and
plants based on the close collaboration with the world of farming, research,
environment, consumers and with local institutions
PRODUCTSInnovative bioplastics and biochemicals based on renewable resources,which are biodegradable and compostable according to the most important international standards.
Solutions economically and environmentally sustainable in specific application sectors with a view to rethinking the overall system.
Bioeconomy as territorial regenerationTransition from a product-based economy to a system-based economy
Adressing societal challenges with bioplastics
UPSTREAM INTEGRATION
TOPSOIL ORGANIC CARBON CONTENT(SOURCE: JRC)
COMPOST AS DRIVER FOR SOILS FERTILITY
DEVELOPMENT OF ORGANIC WASTE SEPARATE COLLECTION
SYSTEMS THROUGH BIOPLASTICS
ORGANIC WASTE IN LANDFILL
Addressing the build-up of a third generation biorefinery for bioplastics and biochemicals
Headquarters and research centre
Novara - Piemonte
Biotechnologicalresearch centre
Piana di Monte Verna (CE)Campania
Mater-Bi productionand research on
intermediates from RRMTerni - Umbria
Mater-Biotech(100% Novamont)
bioBDO productionAdria (RO) - Veneto
Mater-Biopolymer(78% Novamont)
Polyesters productionPatrica (FR)
Matrìca(Versalis/Novamont
50:50 JV)Porto Torres (SS)
Sardegna
Network of sites related to the bioplastics and biochemicalsvalue chain and based on Novamont technologies
Mater-Bi®: applications
Tailor-made applications where biodegradability and compostabilitypresent added value
Matrìca (50:50jv EniVersalis/Novamont)Production Cycle From Oil to Chemicals
BIOMONOMERS PLANT: VEGETABLE OIL FEEDSTOCK. PRODUCTION CAPACITY: 35,000 TON/YESTERS PLANT: PRODUCTS FOR SPECIALTY APPLICATIONS: 2 INDEPENDENT AND FLEXIBLE PRODUCTION LINESADDIVES PLANT: ADDITIVES FOR RUBBERS AND POLYMERIC PLASTICIZERS
Biomonomers
Plant
Glycerin
Intermidiatesfor extensor oil
PelargonicAcid
Azelaic acid
Polymersand rubberadditives
plant
Pelargonic acid estersEsters plant
Fatty acidsblend
Extensor oil
Plasticizers
Esterificationreagents
Complex esters
Note: simplified scheme
Vegetable oil
Chemicalsand reagents
market
C5-C9 acid blend
C5-C9 esters
THISTLE AND OTHER
OLEAGINOUS CROPS
New Biochemicals: Sectors where Matrìca Products willContribute to the Quality of the Environment
PLASTICIZERS FOR PVC AND OTHER POLYMERS AS REPLACEMENT OF PHTALATES
BIOLUBRICANTS FOR AGRICULTURE, MARINE AND INDUSTRIAL APPLICATIONS (HIGH LUBRICITY, BIODEGRADABILITY, LOW FLAMMABILITY)
PALM OIL FREE COMPONENTS FOR COSMETICS
OIL EXTENDERS FOR RUBBER
BIO-HERBICIDES FOR INTEGRATED AGRICULTURE
WORLDWIDE
PRODUCTION OF PHTALATES: 5.5 MIO TON
EU PRODUCTION OF LUBRICANTS: 5.2 MIO TON
HYDRAULIC FLUIDS: 0.7 MIO TON
EUROPEAN PRODUCTION:
> 0.5 MIO TON
BIOPLASTICS: PROPRIETARY MATER-BI OF THIRD GENERATION (WITH AZELAIC ACID)
FEEDSTOCK WITH VALUE ADDED FOR PRODUCTS AND ENERGY
PHASE 1: INDUSTRIAL PROJECT READY FOR APPROVAL «STEAM PRODUCTION AND DIATHERMIC OIL HEATING»
PHASE 2: 2ND GENERATION SUGARS FOR FERMENTATION
ROOTS (ORGANIC SUBSTANCE)
NEW DEVELOPMENTS IN PROGRESS FOR END OF CYCLE RECOVERY
OIL AND PROTEIC FLOUR FOR ANIMAL FEED
NEW CRUSHING TECHNOLOGY PATENTED AND PROVEN AT PILOT SCALE. ENGINEERING IN PROGRESS:25% OIL, 70% PROTEINS, 5% ACTIVE MOLECULES
RAW MATERIALS AND USES FROM THISTLE (six years cycle)
0,9-2ton/ha
12-20ton/ha
STARTED IN UMBRIA MORE THAN 10 YEARS AGO WITH THE AIM TO CREATE A NEW COOPERATION MODEL BETWEEN INNOVATION INDUSTRY AND FARMERS FOR LOCAL REGENERATION, STARTING FROM VEGETABLE OILS AND THE BIOPLASTICS CHAIN
TODAY: FIRST PRODUCTS ARE READY TO BE MARKETED BY FARMING CONSORTIA (CONSORZI AGRARI)
PORTO TORRES: UP TO NOW, 4 YEARS OF EXPERIMENTAL ACTIVITY ON DRY CROPS (AGRONOMIC PROTOCOLS, MECHANISATION, LOGISTICS, GENETIC IMPROVEMENTS, ETC.), BIOMASS/OIL USE WITH MATRICA, ANIMAL FEED WITH SHEPHERDS
OVERALL AGREEMENT NOVAMONT/COLDIRETTI SIGNED IN JANUARY 2015
Novamont/Coldiretti long-lasting relationship
BIO-BASED PRODUCTS: SUPPORT BIO-BASED PRODUCTS RESULTING FROM INTEGRATED VALUE CHAINS, WITH A RRM CONTENT >50%, WHEN SOLVING SPECIFIC ENVIRONMENTAL ISSUES (I.E. BIODEGRADABLE COMPOSTING BAGS/SHOPPING BAGS, USE OF LOW-IMPACT RENEWABLE LUBRICANTS, MULCH FILMS, BIO-ERBICIDES ETC., MARKETED THROUGH THE ITALIAN FARMERS CONFEDERATION NETWORK)
BIOGAS
BIOMASS
OIL
ACTIVE MOLECULES
Coldiretti - CAI/FAI - Novamont Agreement on Thistle
COOPERATION WITH MATRÌCA, COLDIRETTI, ACADEMIA, NATIONAL RESEARCH COUNCIL (CNR), AGRICULTURAL RESEARCH COUNCIL (CRA), NATIONAL AGENCY FOR NEW TECHNOLOGIES, ENERGY AND SUSTAINABLE ECONOMIC DEVELOPMENT (ENEA), FARMERS, SHEPHERDS,
START-UPS, LOCAL INDUSTRY
INPUTS
BIO
PLA
STIC
SB
IOLU
BR
ICA
NTS
BIO
CH
EMIC
ALS
NOVAMONT
CAI
FAI
TRINASEED
AGRONOMICPROTOCOLS
NEWMACHINERY
BIODEGRADABLEMULCH FILMS
BIOLUBRICANTS
BIOHERBICIDES
FAR
MER
S
SEEDS
ROOTS
NEW CRUSHING
PROTEINS
OTHER CHEMICALS
STEAM DIATHERMIC OIL
OTHER CHEMICALS
SHEPHERDS
MATRÌCA
NOVAMONT
NOVAMONT
NOVAMONT
MATRÌCA
FARMERS, OTHERS
SHEPHERDS
NOVAMONT TECHNOLOGIES
MUNICIPAL ORGANIC WASTE COMPOSTING PLANT
*
*
*
**
*
*FLAGSHIP PLANTS
*PILOT PLANTS
ENGINEERING
COOPERATION NETWORK
USE OF LOCAL PLANTS
LESSONS LEARNED
NEW PRODUCTS AND TECHNOLOGIES ARE AVAILABLE, AS WELL AS MANY CASE
STUDIES OF SYSTEM BASED ECONOMY, WHICH CAN BECOME CATALYSTS FOR A FASTER
GROWTH.
CRISIS AT A CERTAIN EXTENT IS A RESULT OF OUR INABILITY TO CHANGE MODEL. IF
POLICIES WILL NOT BE ABLE TO LEVERAGE FROM WHAT ACHIEVED TODAY, THE COSTS
OF INACTIVITY WILL BE DRAMATICALLY HIGH.
A CHANGE OF MINDSET IS NEEDED: BIOECONOMY IS NOT JUST DEALING WITH
RENEWABLE RESOURCES, BUT WITH TERRITORIAL REGENERATION AND CULTURAL
CHANGE, PROMOTING THE CONCEPT OF SUSTAINABLE REGIONS: RECOVERY OF
ABANDONED LAND FOR SUSTAINABLE PRODUCTIONS, SOIL IMPROVEMENT,
REINDUSTRIALIZATION OF DEINDUSTRIALIZED/POLLUTED SITES, RETHINKING OF
AGRICULTURAL VALUE CHAINS NOT ECONOMICALLY SUSTAINABLE THROUGH NEW
INTEGRATED TECHNOLOGIES, LAUNCH OF INTEGRATED AGRO-INDUSTRIAL PROJECTS
ALONG THE VALUE CHAIN.
Thank you!
« The challenge of our millennium is in the balance between the technical means that humanity possesses and the wisdom in how
we will make use of them »Umberto Colombo
1. 6 YEARS CONTRACTS2. AGRONOMIC SUPPORT AND AVAILABILITY OF EQUIPMENT FOR AGRICULTURE 3. PREDETERMINED PRICE FOR SEEDS AND BIOMASS FOR THE FIRST 3 YEARS4. TRANSFER OF A QUOTA OF THE PROTEIN FLOURS RESULTING FROM OIL
EXTRACTION (USEFUL FOR ANIMAL FEED)5. SUPPLY OF ALL THISTLE SEEDS AND BIOMASS TO NOVAMONT FOR 6 YEARS6. MANAGEMENT OF POST-HARVEST STOCKS7. GUARANTEED MINIMUM REMUNERATION FOR FARMERS
Coldiretti - CAI/FAI - Novamont Agreement
Potential scenario in case of 100,000 ha dedicated to thistlecrop vs 2.8 MIO ha of abandoned Italian land
3,000 - 5,000 TON/Y
1.5 MIO TON/Y
370,000 -500,000 TON/Y
250,000 -350,000 TON/Y
40,000 -80,000 TON/Y
110,000 -200,000 TON/Y
PROTEINS FOR ANIMAL FEED (26%)(SARDINIA ANNUAL IMPORT OF FEED: ABOUT 140,000 TON/Y)
VEGETABLE OIL
BIOPLASTICS AND BIOLUBRICANTS
ACTIVE MOLUCULES (STABILISERS, NUTRACEUTICS)
LIGNOCELLULOSIC BIOMASS (AROUND 1 MIO FOR ENERGY AND THE REST FOR SUGARS)
2ND GENERATION SUGARS (TO FEED CHEMICAL AND FERMENTATION PLANTS WITH TECHNOLOGIES ALREADY TESTED OR UNDER TESTING)
Mutual benefits for the local area, the industry and the primary sector
PRIMARY SECTOR
NEW INCOME OPPORTUNITIES
REDUCED DEPENDENCY ON ABROAD FOR PLANT PROTEINS FOR ANIMAL
FEED
CULTIVATION OF ABANDONED LAND (NOT PROFITABLE FOR FOOD
PRODUCTION)
INDUSTRY
INNOVATIVE BIOPRODUCTS WITH LOW ENVIRONMENTAL IMPACT
SHORT AND INTEGRATED SUPPLY CHAIN
REDUCED DEPENDENCY ON ABROAD FOR BIOMASS SUPPLY
SOCIETAL AND ENVIRONMENTAL BENEFITS
SHARED MODEL OF BIOECONOMY AS TERRITORIAL REGENERATION
LOCAL DEVELOPMENT
PROTECTION OF THE ENVIRONMENT AND OF THE BIODIVERSITY
NEW JOBS
NEW GROWTH ALL ALONG THE VALUE CHAIN, INCLUDING DOWNSTREAM AND SATELLITE INDUSTRIES
Map of research on dry crops in Italy
• Agronomic aspects
• Soil preparation
• Weed control
• Fertilization
• Entomology
• Mecanization and logisticaspects
• Agricultural valuations
• Genetic improvements
• Active molecules extraction
• Crushing/Oil production
and modification
• Proteic Meal
• Sugars from biomass
• Fermentation
• Energy from biomass
Filarete Servizi - Milano
CRA ING - Treviglio
Novamont - NovaraMatrìca - Novara
AgriNewTech - Grugliasco
Matrìca - Porto Torres
CNR - Sassari
Università Sassari
CRA ING
Monterotondo
CNR - Catania
ENEA - Trisaia
CRA CIN - Bologna
Novamont - Terni
Università di Perugia
Novamont - Piana di
Monte Verna
The thistle: different uses and development conditions
Oil and proteic flourfor animal feed
Feedstock with value addedfor products and energy
RootsOrganicSubstance
AFTER 3 CONSECUTIVE YEARS OF EXPERIMENTATION: 400 HA AND MORE THAN 40 FARMERS INVOLVED BIOMASS PRODUCTION > 15 TON/HA (17 TON/HA IN 2014) SEEDS PRODUCTION 1,5 TON/HA (1,74 TON/HA IN 2014)
ENGINEERING OF SPECIFIC FARMING MACHINES SUITABLE FOR SARDINIAN STONY GROUNDS
Potential areas for thistle production
HARABLE LAND IN SARDINIA:JUST IN SASSARI PROVINCE 70,000 HA OF HARABLE LAND
LOST FROM 1982 TO 2010(SOURCE: ISTAT)
SARDINIA ANNUAL IMPORT OF FEED: ABOUT 140,000 TON/Y
Supply basin for thistle biomass
NOVAMONT/COLDIRETTI COMMON VISION
CONTINUOUS INNOVATION
(OM PRODUCTS, PROCESSES, PLANTS, ALLIANCES ETC.)
TO CATALYSE
AN INTEGRATED AGROINDUSTRIAL VALUE CHAIN
PROMOTING THE CONCEPT OF
SUSTAINABLE REGIONS, AND CIRCULAR ECONOMY,
STARTING FROM LOCAL ISSUES
TO BE TRASFORMED IN OPPORTUNITIES
IN THE LOGIC OF THE EFFICIENT USE OR RESOURCES
Bioeconomy: taking stock and moving forward
EU Bioeconomy Strategy: a triple challenge
1. producing biomass without overexploitation
and negative impact on the environment;
2. reducing GHG emissions;
3. ensuring economically viable production
that benefits the whole value chain.
Lessons learned from the 3rd EU Bioeconomy
Conference (Turin, 8-9th October 2014) :
new products and technologies and case
studies of system based economy available
at EU level: catalysts for a faster growth;
crisis as a result of our inability to change
model: need for leverage policies;
Bioeconomy: not just dealing with renewable
resources, but with territorial regeneration
and cultural change.
SUSTAINABLE REGIONS
AS FOR «COVENANT OF
MAYORS» SYSTEM
RECOVERY OF
ABANDONED LAND FOR
SUSTAINABLE PRODUCTION
SOIL IMPROVEMENT
REINDUSTRIALIZATION OF
DEINDUSTRIALIZED/POLLUTED
SITES
NEW INTEGRATED
TECHNOLOGIES TO RETHINK
AGRICULTURECONNECTING
NEW FLAGSHIPS
AND RENEWABLE
ENERGY
CONNECTING COMPLEMEN
TARY FUNDING
OPPORTUNITIES
INTEGRATED AGRO-
INDUSTRIAL PROJECTS
MULTIPLE USE OF LOCAL
BIOMASS, FEED PRODUCTION, BIOPRODUCTS