Periodic Reporting for period 2 - MODEL2BIO (MODELLING TOOL FOR GIVING VALUE TO AGRI-FOOD RESIDUAL STREAMS IN BIO-BASED INDUSTRIES)
Reporting period: 2021-11-01 to 2023-10-31
Waste disposal/processing is the second major challenge for our society. In 2018, the total waste generated in the EU-27 amounted to 2.277 million tons, of which 88 million tonnes corresponded to unavoidable food supply chain wastes from farm to fork, and food wastes in the later stages of the supply chain (retail and households). One of the aims of the European Green Deal and the Farm to Fork Strategy is to determine the food waste targets for each EU member in 2023, to define strategies to reduce waste by 30% by 2025 and in 50% by 2030. In turn, EU waste policy aims to contribute to the circular economy by extracting value-added resources from waste as much as possible, minimising the final generation of waste.
In this frame, agri-food residual streams are a potential substitute for fossil-based resources and have an important added value, if these are used as feedstock in bio-based industries (BBIs). However, most organic residual streams present a high complexity and a heterogeneous mixture, which makes the production and separation of specific compounds difficult. Furthermore, the variability of quantity and physico-chemical composition of these streams and their seasonality reduce the technological and economic feasibility of the conversion processes to valuable products. Therefore, a deeper knowledge of the composition, logistics and volume of organic residual streams could support the decision-making process to maximise the benefit of a specific raw material and select the most appropriate technologies for its optimal recovery.
The project MODEL2BIO aims to create a Decision Support System (DSS) tool for managing residual streams produced in agri-food companies. This is an innovative concept that using predictive models allows selecting the best ways to value these streams considering their composition, logistic and industry location among other factors. This innovative MODEL2BIO-DSS tool is based on the interconnection of 3 complementary elements: Simulation Module, Optimisation Algorithm and LCA module.
Model2Bio simulates the entire value chain providing recommendations from a holistic perspective (technical, economic, environmental and social). This provides a new concept for waste management.
In this frame, agri-food residual streams are a potential substitute for fossil-based resources and have an important added value, if these are used as feedstock in bio-based industries (BBIs). However, most organic residual streams present a high complexity and a heterogeneous mixture, which makes the production and separation of specific compounds difficult. Furthermore, the variability of quantity and physico-chemical composition of these streams and their seasonality reduce the technological and economic feasibility of the conversion processes to valuable products. Therefore, a deeper knowledge of the composition, logistics and volume of organic residual streams could support the decision-making process to maximise the benefit of a specific raw material and select the most appropriate technologies for its optimal recovery.
The project MODEL2BIO aims to create a Decision Support System (DSS) tool for managing residual streams produced in agri-food companies. This is an innovative concept that using predictive models allows selecting the best ways to value these streams considering their composition, logistic and industry location among other factors. This innovative MODEL2BIO-DSS tool is based on the interconnection of 3 complementary elements: Simulation Module, Optimisation Algorithm and LCA module.
Model2Bio simulates the entire value chain providing recommendations from a holistic perspective (technical, economic, environmental and social). This provides a new concept for waste management.
To achieve the ambitious goal, the work has been organised into 2 groups of parallel but closely interrelated tasks: mathematical modelling tasks and experimental tasks. The mathematical modelling tasks are focused on the construction of the different elements of the MODEL2BIO-DSS tool; whereas the experimental tasks focus on extracting, compiling, and synthesising all the information required for the appropriate construction, calibration and validation of the mathematical tools.
The main experimental tasks carried out have been the following:
- Agri-food residual streams characterisation at physicochemical & microbiological level: meat sector (poultry; pork and veal); vegetable sector (tomato, pepper, potato, artichoke); dairy sector (cheese, milk), and alcoholic beverages sector (beer, wine) including seasonal variability.
- Analysis of 2 new techniques to stabilise agro-food residual streams: Microwave dehydration technology and pre-fermentation for stabilisation.
- Analysis of technologies to obtain value-added products: Different extraction and purification processes for the recovery of selected residual streams (SFE-CO2, SCE-H2O, & solvent extraction) have been developed in lab and pilot scale and different high throughput fermentation processes are carried out at lab and pilot scale.
Regarding modelling tasks, a complete bibliographic review has been carried out (mathematical models, agri-food companies, intermediate processes, and BBIs) to define the characteristics of the models developed in the Simulation module.
- A flexible and easily adaptable version of the Simulation module has been developed. This module can predict the mass fluxes for any bio-based residual stream alternatives using a set of compatible model libraries describing the agri-food production lines, the intermediate processes, and the final valorisation in BBIs. The Plant-wide modelling methodology was proposed by CEIT as a systematic methodology for constructing mathematical models able to describe the whole systems as complex as required in each case study. The organised structure that this methodology presents enables the straightforward incorporation of transformations, allowing the library to be continuously updated.
- The LCA module developed can estimate the environmental, economic and social impacts associated with any bio-based residual stream alternative using an LCA methodology.
- The Optimisation algorithm developed can automatically select the bio-based residual stream alternatives that minimise a global cost function previously defined using the mathematical models.
After the integration of the three modules, a verification of the MODEL2BIO-DSS tool has been carried out in the three validation areas: Northern Spain, Flanders (Belgium) and Western Macedonia (Greece).
Regarding non-technical tasks, the project key exploitable results has been characterised, and the bases for the Intellectual Property Rights Protection have been defined.
Finally, the Communication and Dissemination Master Plan has been prepared. The Model2Bio webpage is hosted at http://model2Bio.eu/. Due to the industrial and scientific nature of the project, the presence of the project in Twitter (@Model2bioEu) and LinkedIn was set up (www.linkedin.com/company/model2bio/about). The ESCI YouTube channel is being used to reach a greater audience. On this channel, Model2Bio received a dedicated playlist. All project related videos and interviews have been uploaded to this playlist (the explanatory promotional video, 7 video interviews, the final video and the final workshop).
The main experimental tasks carried out have been the following:
- Agri-food residual streams characterisation at physicochemical & microbiological level: meat sector (poultry; pork and veal); vegetable sector (tomato, pepper, potato, artichoke); dairy sector (cheese, milk), and alcoholic beverages sector (beer, wine) including seasonal variability.
- Analysis of 2 new techniques to stabilise agro-food residual streams: Microwave dehydration technology and pre-fermentation for stabilisation.
- Analysis of technologies to obtain value-added products: Different extraction and purification processes for the recovery of selected residual streams (SFE-CO2, SCE-H2O, & solvent extraction) have been developed in lab and pilot scale and different high throughput fermentation processes are carried out at lab and pilot scale.
Regarding modelling tasks, a complete bibliographic review has been carried out (mathematical models, agri-food companies, intermediate processes, and BBIs) to define the characteristics of the models developed in the Simulation module.
- A flexible and easily adaptable version of the Simulation module has been developed. This module can predict the mass fluxes for any bio-based residual stream alternatives using a set of compatible model libraries describing the agri-food production lines, the intermediate processes, and the final valorisation in BBIs. The Plant-wide modelling methodology was proposed by CEIT as a systematic methodology for constructing mathematical models able to describe the whole systems as complex as required in each case study. The organised structure that this methodology presents enables the straightforward incorporation of transformations, allowing the library to be continuously updated.
- The LCA module developed can estimate the environmental, economic and social impacts associated with any bio-based residual stream alternative using an LCA methodology.
- The Optimisation algorithm developed can automatically select the bio-based residual stream alternatives that minimise a global cost function previously defined using the mathematical models.
After the integration of the three modules, a verification of the MODEL2BIO-DSS tool has been carried out in the three validation areas: Northern Spain, Flanders (Belgium) and Western Macedonia (Greece).
Regarding non-technical tasks, the project key exploitable results has been characterised, and the bases for the Intellectual Property Rights Protection have been defined.
Finally, the Communication and Dissemination Master Plan has been prepared. The Model2Bio webpage is hosted at http://model2Bio.eu/. Due to the industrial and scientific nature of the project, the presence of the project in Twitter (@Model2bioEu) and LinkedIn was set up (www.linkedin.com/company/model2bio/about). The ESCI YouTube channel is being used to reach a greater audience. On this channel, Model2Bio received a dedicated playlist. All project related videos and interviews have been uploaded to this playlist (the explanatory promotional video, 7 video interviews, the final video and the final workshop).
The main objective of the Model2Bio project is to develop and validate a pioneering DSS Tool, based on mathematical models to predict agri-food residual streams and to identify best routes for valorising them.
Expected results:
‒ A DSS Tool
‒ Simulation Module & Model Libraries
‒ Microbial composition of various agri-food residual streams and analysis of their interference in fermentation processes
‒ Methods to stabilise agri-food residual streams
‒ Extraction and purification process for residual stream valorisation
‒ Valorisation of various agri-food residual streams by fermentation
Expected impact:
- Better insight about the organic residual stream
- Thorough knowledge about the most relevant processes in which the agri-food industry residual streams can be reused to obtain added-value bio-products and energy
- 10% improvement in the yields of fermentation processes, and 20% in the yields in extraction processes
- To increase income and business opportunities for agri-food and waste management companies
- A stronger and more sustainable EU food and drink industry, more environmentally friendly and profitable
- For BBI, new market opportunities for the use of renewable resources. Turning residue management problems into economic opportunities
- As a Circular Economy project, it has the potential to create new job opportunities. It is expected that 5 new jobs are going to be created within Model2Bio project
Expected results:
‒ A DSS Tool
‒ Simulation Module & Model Libraries
‒ Microbial composition of various agri-food residual streams and analysis of their interference in fermentation processes
‒ Methods to stabilise agri-food residual streams
‒ Extraction and purification process for residual stream valorisation
‒ Valorisation of various agri-food residual streams by fermentation
Expected impact:
- Better insight about the organic residual stream
- Thorough knowledge about the most relevant processes in which the agri-food industry residual streams can be reused to obtain added-value bio-products and energy
- 10% improvement in the yields of fermentation processes, and 20% in the yields in extraction processes
- To increase income and business opportunities for agri-food and waste management companies
- A stronger and more sustainable EU food and drink industry, more environmentally friendly and profitable
- For BBI, new market opportunities for the use of renewable resources. Turning residue management problems into economic opportunities
- As a Circular Economy project, it has the potential to create new job opportunities. It is expected that 5 new jobs are going to be created within Model2Bio project