Cost of manual harvest: 3kg of fruits per hour, 333 hours per to = US$ 85, plus 50% for fruit to seed preparation = US$ 120 – 125, no overhead no depreciation, no profit
12/13/09 BPL farm land Capital area (population 3 Mio) International Airport Atlantic Seaport 50 km radius
12/13/09 To Tema/Accra Test Farm Lomobiawe West Lomobiawe South Lomobiawe North Adibiawe North Adibiawe South To Aflao
12/13/09 December 2008 June 2009 Before we started the test farm Jatropha hedges planted in Dec 2008 Maize planted in May 2009 Transformation of Savannah soil is already visible
Jatropha Curcas Linn (JCL) centered business model proved too risky
Stand alone JCL farm for Biodiesel is currently not profitable (in most cases)
Future, high value products not fully defined (Biojetfuel, Biorefinery)
Technologies for reduced production cost of seeds lag behind
Measures for drastic overall yield improvements are necessary
Increased mechanization required, especially for harvesting
Early revenue streams had to be identified for better cash flow
Multiple revenue streams had to complement each other
Risk exposure needed reduction to an acceptable level
Unquestionable levels of sustainability had to be achieved
Agronomic sustainability
Ecological sustainability
Social sustainability
Economic sustainability
Food vs Fuel issues had to be addressed
African specific issues required adjusted solutions
12/13/09
Value chain is financially not working out for early producers
Current use of C rude J atropha O il (CJO):
Biodiesel
Electricity and heat from cogeneration
Testing of future applications (Biojetfuel, Refining of specialty oils)
Assume a cif Rotterdam price of US$ 1000 per MT
(Already absolutely unrealistic for biodiesel & power generation!) results in approx. US$ 900 FOB Africa
Translates in ex mill price of US$ 750 – 850 depending on location
Packaging for transport US$ 100
Processing US$ 60
Seeds plus transport US$ 600
4 MT seeds needed per MT of CJO
Assumed price of seeds at farm gate US$ 100 (doesn’t cover all of direct cost on commercial farm!)
Shipping and handling of seeds US$ 50
Optimistic cash flow projection per MT of CJO: US$ - 10 to + 90
12/13/09
JCL business will work when/if seed prices come down and revenues go up
Cost of seeds will come down, when
JCL specific mechanization technology becomes available
Harvesting
Pruning
Improved agronomic methods are developed and tested
Depreciation comes down due to reduced capital expenditure per ha
Revenues will go up, when
Advanced uses of CJO go online which justify higher feedstock prices
Press cake can be sold at a reasonable price
CJO as feedstock for biorefineries becomes a reality
Solutions are needed to bridge a 3-5 year market build up
12/13/09
Theoretical yield calculation for an excellent mature JCL field
= 7980 kg seeds or 1995 kg oil
12/13/09 Factor Number of plants Harvests per year Number of branches Number of clusters Fruits per cluster Seeds per fruit Seeds per kg Oil extraction rate influenced by > planting pattern > climate > pruning technique > soil quality, fertilizer > pollination, bees > --- > variety > technology, variety numbers 1900 x2 x35 x3 x10 x3 /1500 25% (mechanical extraction)
Polyculture instead of JCL with some intercropping
Availability of multiple revenue streams to generate early income
Integration of the best properties from all types of crops
Full sustainability within minimum time frame
2 nd Gen Biofuel and biochar from up to 10 MT/ha of waste biomass
Overall negative carbon footprint through biochar sequestration
Zero waste approach
Develop synergies between various revenue streams
Maximum JCL yield requires bees for pollination
Waste biomass handling produces fertilizer
BTL reduces fuel cost at farm and supplies energy for processing
Biochar for soil improvement also creates carbon credits
Essential to give the same amount of attention to each revenue stream
12/13/09 Additional Revenue Streams Slowly growing processing of JCL seeds Charcoal production in kilns Roll out of bee hives and their population General plantation roll out of total area (up to 5000ha per farm) Early plantation roll out (up to 1000ha) Testing and preparation Food crop planting on maximum field size available for early revenue generation Plantation Development Proper clearing and plowing Application of standard fertilizer and water management Use of Jatropha DOC replacing standard NPK Biochar program Soil Management Carbon credits for CO2 sequestration
A multi stream project requires strong complexity management
Project needs break down into small, transparent sections
Thorough testing prior to roll out is obligatory
Testing helps to adjust basic methods and techniques to the actual project environment
Specific crops react differently in a farm specific environment
Leadership team, supervisors and personnel need to be trained and tested
Build a detailed business case based on realistic data
Plan with proven data only, no hearsay from the internet
In depth continuous risk assessment
Permanently review and revise business model
New information from internal and external sources to be checked for relevance
Recognized errors and mistakes have to be corrected immediately
Manage cost daily on detail level
Build and improve revenue constantly
Strong strategic model couples with everyday simplicity
12/13/09
Adjust technology to local conditions
Manual labor vs. mechanization
Preference for manual labor
Often the lower cost alternative
Better quality plant handling
Supports social sustainability
Governed by availability of workforce
Time available for a job
Yield targets start very low
Below 60% of standards advertised
Usage of open pollinated planting material when ever possible
Development of an outgrower program early on
Social responsibility to be exercised all the way
Strong focus on community relations
12/13/09
Nothing is taken for granted
Study of environmental conditions
Soil, nutrients
Climate
Water rain/irrigation situation
Local pests and rodents
Development of a first set of low risk cash crops (i.e. Maize, Sorghum, Millet)
Identify best Jatropha planting method
Timing
Equipment selection (types & numbers)
Investment limited to the absolute essential
Use of locally available services
Labor before mechanization
Low operating cost
Focus on essential information not perfection of operations
Recording of all details and constant strategy review
Identification and planning of all acquisition of equipment, resources and material for roll out
Time required: 15 months
12/13/09
Detailed planning of all aspects in this phase
Continuously improve business plan
Follow up on all assumptions made
Adjust to reality (cost, yields, market prices)
Permanent update of risk assessment
Use enough land to reach stand alone profitability
Planting approach
Limited number of cash crops used
Start systematic Jatropha maintenance / pruning
Start own seed program through selection
Continue testing
Test as many crops as possible
Continuously adjust strategy as needed
Time required 12-18 months
12/13/09
Further roll out to the final size intended at a suitable speed
Roll out speed depends on financing strategy
Firm strategy with little variance should be built by now
Change the plantation economics
Plantation should constantly remain in a profitable state
Soil improvement program combined with permanent test efforts by now allows for higher value crops in the early developed fields
12/13/09
12/13/09
After extensively testing many different planting patterns a double hedge row system was chosen
Best use of available space
Enables efficient mechanization for cash crops
Enables mechanical JCL harvesting
Approx 1900 JCL plants per ha 3.0 m 3.0 m 3.0 m 3.0 m 1.5 m 1.5 m 1.5 m 1.5 m 10.0 m 10.0 m 10.0 m Space for cash crops, i.e. maize, sunflower, sorghum, soy, beans, groundnut Space for cash crops, i.e. maize, sunflower, sorghum, soy, beans, groundnut Space for cash crops, i.e. maize, sunflower, sorghum, soy, beans, groundnut
12/13/09 October 2009, 8 weeks after planting
It is difficult to determine the optimal split of land use between JCL hedges and food crops
High flexibility is built into our double hedge system
Adjustments should be made based on selected crops
Degree of mechanization and equipment used
We look for a planting pattern that is adjustable later on
Food crop area should be measured in a way that additional JCL hedges can be added later on
Example: 10m wide area can be split later by another double hedge in two 3,5m wide areas
12/13/09
Maize is our baseline crop
Locally available market infrastructure with transparent prices
Crop rotation is a necessity
Rotation crops will be determined year by year based on situation
Possible rotation cash crop examples: Sunflower, Sorghum, Soya
Castor as a high value oil plant
Many higher value crops:
Water melon, egg plant, tomato, hot and sweet pepper, onions, groundnut, okro
Crop selection based on market security and price levels
Detailed feasibility study before large scale planting
Logistical advantage
Focused on local food markets (Vegetables for Accra & Tema markets)
Replace imports on cash crops
Irrigation program for best suited fields
Minimum additional 100ha per year
Up to 4 high value planting seasons feasible per year
Off season harvesting with exceptionally high market prices
12/13/09
African origin where ever possible
Domesticated African if necessary
Open pollinated seeds have preference over hybrids
Strictly no genetically manipulated material
BPL actively supports African seed development initiatives
BPL promotes an open seed exchange mechanisms for African farmers
Out growers/smallholders will always be given a choice of open pollinated seeds
12/13/09
No proven superior planting material identified yet
Experiments with seeds from different regions/sources including low toxin materials show no obvious superior material
Agronomic practices and soil quality are key success factors
Difficult choice between seedlings, cuttings, direct seeding
Cuttings currently have the strongest arguments on their side
Fastest growth
Best selection possibilities
Near 100% success rate
Best pest resistance
By far the most economic planting method
Special test currently under way: direct seeding with pre-germinated seeds
Maintenance
Keep weeding to the essential minimum
Perfect pruning technique is essential for yield management and mechanical harvesting
JCL specific mechanization essential for stand alone profitability
Soil preparation and improvements
Initial one-time deep plowing
Addition of biochar and microorganisms
Water management
In high humidity climates rain is not essential for good growth
Measures to capture condensation are easy and advisable
12/13/09 Simple way to capture early morning humidity
12/13/09
Tropical savannah soils are extremely low on nutrients and organic matter
Unsustainable African agriculture practices are further degrading the soils through common slash and burn methods and migrant farmers
Resulting erosion adds to the problem
Burning sun quickly consumes organic matter
Wind and rain wash out the nutrients
Effective soil management requirements
Increased shade with stronger vegetation
Stop erosion from wind and rain
Improved storage capacity for water and nutrients in the soil
12/13/09
Concept is based on continuous improvement cycles
Jatropha hedges
Roots extract nutrients from lower levels of the soil
Increase humidity storage in root system and through more shade
Add organic matter and nutrients to top soil due to very fast growth
Reduce erosion by wind and heavy rains
Fast growing cash crops
Add organic matter to the soil (i.e. corn stover)
Nutrients build up through fertilizer application
Reduced new weed build up saves water and nutrients
Application of natural fertilizers
Animal manure
Human sewage (under investigation)
Returning Jatropha press cake to the field
Adds high value nutrients and organic matter
Biochar program in combination with microorganism build up
Builds up long term fertile soil (terra preta) for high value crops
12/13/09
It is essential to get sustainable on nutrient application ASAP
Initially it is unavoidable to use standard NPK for the cash crops
Some positive side effect of surplus nutrients for the Jatropha hedges will occure
As soon as Jatropha press cake becomes available it will replace NPK
Jatropha press cake has a nutritional value similar to that of chicken manure
Research data suggests that maize reacts better to Jatropha press cake than to NPK
Long term JCL press cake may also get useable as animal feed after detoxification
Through a biochar/mycorrhizae program a completely new fertilization method will be designed
Balanced crop rotation and cover crops will be utilized to reduce external fertilizer application needs and cost
12/13/09
Utilization of the high humidity (80 – 85% near year round)
Capturing the morning condensation is sufficient for growth all the way through the dry season
Shade from JCL bushes reduces evaporation from condensation water on the ground and the leaves
Flood control measures
Drainage channels
Surface shaping
Control of water logging
Planting pattern
Irrigation systems to be built for the best suited fields
12/13/09 Seedlings in a furrow covered by cashew leaves thriving during the hottest period of the dry season
The BIONIC GROUP’s microfuel technology
Products:
2 nd generation drop-in diesel fuel from biomass feedstock
Biochar for soil improvement and carbon sequestration
Proven process which utilizes microwave and zeolite catalysts
Other biochar producing technologies
Many low cost alternatives available with higher biochar output but usually no fuel
Biochar plus microorganisms create a new kind of top soil
Possible side products
Char from the microfuel process is a high quality thought after product with very special properties ideal for replacing fossil carbon in many uses
Activated carbon for filter technologies
Replacing fossil coal in steel production with very high carbon credit potential
Carbon for tire manufacturers
Solid fuel for electricity generation with carbon credit potential
12/13/09
Honey business
Excellent business in its own right
Positive side effects for Jatropha pollination
Additional possibility to generate jobs for community
Solid fuel & Charcoal
Wood waste from clearing
Wood waste from pruning Jatropha
Carbon credits
Copenhagen conference Dec 2009
Carbon credits for biochar will most likely be possible after 2012
Green energy & Biochar
Biofuel, optionally Biogas
Electricity from Biofuel or Biogas
12/13/09
Food to market Jatropha seeds to oil press Waste Biomass Diesel fuel for farm equipment and sale Press cake back to fields as fertilizer Jatropha Oil to markets Field preparation Planted Field Waste wood from clearing Solid fuel (wood pellets) to market Charcoal to market
Soap production (local)
SVO for generators (local)
SVO as transport fuel (local)
Biodiesel production (local& global)
Biojetfuel production (global)
Biorefinery feedstock (global)
microfuel plant Biochar to fields for soil improvement and carbon credits
Some indicative numbers on per ha revenues generated within the model ( Based on a mature, stable state which should be reached after max. 5 years)
12/13/09
Waste biomass from field preparation (brush branches and roots)
Solid fuel for industrial boilers
Charcoal
Cash crop sales (maize)
Multiples of this amount are possible with higher value crops like vegetables
JCL oil sales
Honey sales
JCL press cake cost reduction of fertilizers by
Waste biomass from field maintenance free supply in return for free biochar
Biofuel cost reduction for fuel used at farm
Biochar products (briquettes, etc.) to be determined
Carbon credits from biochar sequestration assuming 2 MT per ha/year
Bionic Palm Ltd, Ghana has developed a unique and h more
Bionic Palm Ltd, Ghana has developed a unique and highly innovative plantation model that is addressing a large number of current issues about African commercial agriculture:
- Food and Fuel instead of Food vs Fuel
- Make African agriculture sustainable
- Reverse degradation of arable land
- Fight hunger and poverty
- Deliver an overall negative carbon footprint
- Offer a safe and profitable investment in Africa for socially conscientious investors less
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