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VOSOLUB PROJECT

VOSOLUB PROJECT. New formulations of sunflower - based bio- lubricants with high oleic acid content XAVIER PAGES-XATART-PARES, ITERG ‘S Technical Manager x.pages@iterg.com. Le R éseau de l’ E xcellence T echnologique. ITERG: French CTI ( Technical Industrial Centre) .

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VOSOLUB PROJECT

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  1. VOSOLUB PROJECT New formulations of sunflower-based bio-lubricantswith high oleicacid content XAVIER PAGES-XATART-PARES, ITERG ‘S Technical Manager x.pages@iterg.com

  2. Le Réseau del’Excellence Technologique ITERG: French CTI (Technical Industrial Centre) • CTI for producers and transformersof fats and oils • Authority : French Ministry for Finance, Economy and Employment • 2012 Budget : 6.3 M € • Staff : 78 • ISO 9001: 2000 certification

  3. A synergy of competences Services provided Industrialenvironment And Safety Quality & safety of products • AnalyticalControls • Production, made-to-orderrefining • Research & Development • Audit • Watch & Information • Professional Training Green Chemistry And Process Nutrition, metabolism & Health Technology Refining

  4. Challenges of green chemistry

  5. CEDOP plateform A EuropeanResearch and Development Centre for the industrial-scale production of bioproducts and green chemistryprocesses (8,8 M€)

  6. Raw materials to bioproducts REFINING Crudeoils Oilseedcrushing Refinedoils Seeds Bioproduits CEDOP PLATEFORM Bioproducts

  7. Our services Coordinating and implementingResearch & Development programmes aimedatdeveloping new processes and bioproducts Transferringprocessesfromlaboratory-scale to pilot-scale production, scale-up and process validation includingeconomical and environmentalevaluation Industrialpre-production models for wide-scale and/or test market formulation testing Customized production of finishedproducts for niche industries

  8. Markets Biosolvents Biosurfactants Biolubricants Biopolymers Biocides & innifuges Cosmetics GMP dedicated technology

  9. LUBRICANTS 5 Milions tons 2006 95% 80% PME 30%

  10. BIOLUBRICANTS • Plant basedlubricants have a number or inherentsqualitiesthatgivethemadvantages over petroleumoils : • reduce impact on humanhealth and environment • use of renewableresources • But , first of all : • Technicalperformances are needed for the wide range of applications • COST has to beunder control ! • fats and oils have to bemanaged,…… « differently »

  11. O O O CH2 - O - C - R1 R2 - C - O - CH CH2 - O - C - R3 Fats and Oils main components areTriglycerides The acid function of 3 fatty acids will react with the 3 alcohol functions of glycerol, building triglycerides out of a new kind of bound called “ester“ Fatty acid (-COOH) + Alcool (-CH2OH)  Ester (-COOC-) + H2O ester bound  Under certain conditions, theester boundmay be disrupted by Glycerol hydrolysis Free FA"Partial" glycerides Glycerol saponification Fattyacids SoapsGlycerol

  12. Fats and Oils main componentsFatty acids A fatty acid is composed of carbon (C), hydrogen (H) and oxygen (O) atoms, organised in long hydrocarbonated chains:  The majority of fats and oils contain fatty acids with 16 and 18 C atoms AND "acidfunction" 0 1 BUT, "double bounds" 2 or 3 Double bounds and acid functions chemically mean reactivity

  13. BIOLUBRICANTS : REQUIREMENTS • One of the most important barriers to the adoption of biolubricants onto the market is their higher price compared to mineral oil based lubricants. In order to improve the market penetration of biolubricants, it is therefore necessary to decrease their purchase cost. • The formulations tested in VOSOLUB project use new bases (developed in the framework of IBIOLAB project) that are obtained from: • A new variety of oil seeds: very high oleic sunflower seeds give an oil with a very good resistance to oxidation and good flow properties. • A new refining process: a soft refining process is used instead of complete and classical refining (reduction of the processing costs due to the tailoring of refining to oils and elimination of useless steps). • The new variety of oil seeds in combination with the soft refining process allow to obtain base oils with high stability, with a low impact on the environment and at a lower cost compared to polyolesters.

  14. VOSOLUB PROJECT : OBJECTIVES

  15. VOSOLUB PROJECT : PREVIOUS EXPERIENCE • The formulations that will be evaluated in VOSOLUB have been previously developed in the framework of IBIOLAB project (Improvement of BIolubricant Manufacturing and Development thanks to the Obtaining of EcoLABels in a wide Range of Industrial Sectors , FP6). • This collective research project brought together 22 partners who represented the whole spectrum of the biolubricant sector – SMEs, R&D performers and associations -from seven countries. • This project has been selectedas excellent projectand sucessstory  • 2 new formulations (hydraulicfluids and grease) of sunflowerbased bio lubricants are alreadyeco-labelled • Ibiolabproject has been done to reach the necessaryspecifications to obtainEuropeanecolabel for lubricants

  16. VOSOLUB PROJECT: PARTNERS

  17. Obtention of VHOSO for lubricant application • it is important to target very high quality crude oil, high in c18 :1, high in tocopherols and adapted to mild refining, • The High Oleic variety sunflower seed comes from special breeding by specialized planting seed breeding companies (without the use of genetic modification). • Because of its low content of polyunsaturated fatty acids (linoleic) while its high content in monounsaturated fatty acids (oleic), the oil from high oleic sunflower seeds has an enhanced fluidity (even at low temperatures) and a better stability (even at high temperatures). The cold flow properties are also further sustained by the low presence of stearic and palmitic acids. • This varietyisprovided by ARTERRIS withquality control allowing to obtain good qualityseeds (low in FFA)

  18. Soft Refining of VHOSOAim of the refining of vegetableoils The objective of the refiningis to remove « objectionable components »

  19. Typicalrefinedoilqualitysheetgeneralspecifications

  20. Typicalrefinedoilqualitysheetcontaminants

  21. TypicalrefinedoilqualitysheetOTHER SPECIFICATIONS • Sometimesfound in industrialqualitysheets • Metal traces : nickel, cadmium, lead arsenic, mercury(max 0.1 to 0.02 ppm) • Microbiologicalcharacteristics • total viable count (<1000 per gram) ,enterobacteria, • moulds, yeasts, lypolyticbacteria (<10 per gram) • and alsoPRODUCT SPECIFICATIONS • IV, fattyacid composition, melting point, N20, rancimat,…...

  22. Removed compounds Reactivesused Reactives used Crudeoil Phospholipides Water degumming Acidconditioning Free fattyacid (soapstocks), phospholipides, H3PO4, métal traces, some pigments, oxidationproductssome contaminants Neutralization H3PO4 (H2O) Phosphoric acid NaOH Caustic soda water Chemical Refining

  23. Washings Centrifugation Washing water (soapstocks, phospholipides) Drying (vacuum) Bleaching Coloured pigments , soap traces, phospholipides traces, Polar oxidationproducts Dewaxing (sunflower) Filtration Deodorization Flavors, tastycompounds,pesticides Blanketing water Nitrogen Activatedbleachingclays Vapor, vacuum High temperature Chemicalrefining REFINED OIL

  24. Soft refining of VHOSO • SOFT REFINING • a process of purification of the chosen raw materials adapted to each targeted application, • allowing to obtain oils with high stability , high tocopherols content • presenting the lowest impact on the environment and a reduced cost • No washings, • no centrifugalseparation, • No waste water, • 20% solidresidu , • -25/30 % energy

  25. Specificationrequirements on soft refinedoil

  26. SpecificationRequirementson Base oil

  27. THANK YOU FOR YOUR ATTENTION

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