Ecreee-unido Bioenergy Crops Assessment Third Report

8/10/2019 Ecreee-unido Bioenergy Crops Assessment Third Report

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Regional potential assessment of novel bio energy crops

in fifteen ECOWAS countries

3rd progress report to ECREEE (and IIB !" I#O$

#ecember %&'%


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'

Contents

1 Background and structure of the project ...................................................................................................................... 2

' ' )eneral introduction to t*e pro+ect %

' % ,*e pro+ect *as been structured in t-o p*ases %

' 3 )eneral intermediate observations and conclusions %

2 Specific conclusions after the first phase ................................. ............................... ................................ ...................... 3

% ' S-eet Sorg*um 3

% % .atrop*a /

% 3 Cassava 0

% / Cas*e- 1

3 Setting the boundaries for economical sustainability .............................. .............................. ................................. ...... 8 4 Jatropha curcas in ali and Burkina !aso ............................... ................................. .............................. ..................... 13

/ ' 2rocessing '/

/ % ass and energy balance '0

/ 3 Current pro+ects '0

/ / Intermediate observations and conclusions '1

" S#eet Sorghum in Sierra $eone and %igeria ............................................................................................................... 1&

0 ' 2rocessing '4

0 % ass balance '4

0 3 Intermediate observations and conclusions %&

' Cassa(a in %igeria and )hana .................................................................................................................................... 2*

1 ' 2rocessing %'

1 % ass and energy balance %'

1 3 Current pro+ects %'

1 / Intermediate observations and conclusions %%

& Cashe# in +est ,frica ............................................................................................................................................... 22

5 ' 2rocessing into bio energy %3

5 % ass balance %3

5 3 Intermediate observations and conclusions %/

,ppendi- 2 $ist of figures and tables ........................................................................................................................................... 2"


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%

1 Background and structure of the project

1.1 General introduction to the project,*e pro+ect 6Regional potential assessment of novel bio energy crops in fifteen ECOWAS countries77 -asstarted by t*e different pro+ect partners based on t*e need identified to ma8e an overall assessment of aseries of ovel potential bio energy crops -*ic* can or could be gro-n and processed in t*e future in t*e'0 ECOWAS countries ,*is pro+ect fits in a broader strategic analysis of alternative energy needs andproduction9 t*e 8ey mandate of t*e main funding partner in t*e pro+ect9 ECREEE ,*e pro+ect partnersdeliberately e:cluded traditional ;7bio energy77 crops li8e sugarcane9 oil palm9 mai


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and larger scale do-n stream prop*ase of t*e pro+ect

2 Specific conclBased on t*e progress report afteselected for furt*er analysis ,*e se

2.1 Sweet SorghumBased on t*e climate based suitabilt*e ECOWAS countries can develSierra eone and igeria *ave comof cassava or sugar cane In co*erefuel9 coo8ing stoves9 *eating -aterare being created Because Bra


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lo-er biomass9 and t*us sugar production9 to be anticipated in t*e traditional grain sorg*um areas in WestAfrica In addition9 t*e crops gro-n in t*ese areas -ill *ave to be t*e sole feedstoc8 for et*anol conversion9

as t*ese areas do not allo- t*e large>scale production of sugarcane or to a lesser e:tend cassavaA p*ased approac*9 -*ere dedicated s-eet sorg*um cultivation can benefit from e:isting cassava orsugarcane to et*anol 8no->*o-9 follo-ed by a smaller scale implementation of dedicated s-eet sorg*umplants moving to t*e nort*ern gro-ing areas9 may be realistic

2.2 Jatrophaali and Bur8ina aso *ave t*e longest record in .atrop*a pro+ects ost of t*ese pro+ects are located int*e Sout*ern part of t*e countries In t*ese areas t*ere is a .atrop*a grain processing capacity and amar8et for t*e .atrop*a oil9 mainly used to po-er 2s9 to produce soap or to be turned into biodiesel ona small scale Bot* countries are land>loc8ed and diesel prices are relatively *ig* ,*e large plantationpro+ects pro+ected for )*ana and Senegal -ere less successful so far and -ere not reali


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0

2.3 Cassava

Based on climate suitability of cassava9 a relatively large portion of t*e ECOWAS region can develop cassavainto a bio energy source It is very critical t*at cassava is produced in first instance as a food crop and t*atsupply for food applications is guaranteed ,able ' summari' 4'3Cape Derde / &33 '&'9& &9&G nd 3 0G' 3 551 >'40)*ana %3G /1& 409& &9'1 %391 '% %3& 1&& / 1&% 05' 5 1%4 &%G)uinea %/0 405 3%9& &9%1 090 G4G 3%1 G4% 00' 1 550)uinea>Bissa 31 '%& 359& &9'& '/95 /0 &&& /3 3G5 ' 1&3Ivory Coast 3%% /1& 0%9& &9%4 '/9' % G&& &&& % '&5 '%% 5G% 454iberia ''' 35& 3&9& &9'1 19& /G3 5&1 00& &&& >01 %G/ali ' %/& &&& G9' &9'4 G9/ 44 '1% %' '%0 15 &35iger ' %15 &&& 49/ &9// 309' '&5 1%0 ''3 %55 >0 10%igeria G%3 514 '/'9& &9/' /G9/ 31 4&/ 3&& '1 4G& 3&0 'G G'3 GG0Senegal 'G1 'G& 0/9& &9%% '595 %10 033 %'% '0' 03 34%Sierra eone 5' 5/& 549& &9%G '395 3/G 1'4 35& %%0 >%& 1&5,*e )ambia '' 3&& '%G9& &9'% %'9G 5 35& 4 'GG >4%G,ogo 01 540 G39& &91' 0191 551 5'0 105 /&0 ''G 3'&,otal 0 ''% G&3 0G &1' G33 %5 533 'G3 3' 3%4 5/&

Cassava

tonnes roots


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1

!igure 3 arget area for further Cassa(a study. /ark green primary focus area0 pale green secondary focus area

,*e et*anol produced from cassava in igeria is not only used as transport fuel It is also put on t*e mar8etfor coo8ing stove fuel9 -ater *eaters9 and ovens In )*ana9 Caltec* Dentures is planning to build a cassavato et*anol plant )*ana is a ma+or producer and e:porter of various cassava products for food and feedCassava for t*e et*anol plant is ideally of t*e so>called *ig*>sugar varieties earning from t*e igeriane:perience9 it -ill be interesting to investigate t*e potential of t*ese cassava varieties for et*anolproduction in )*ana and Benin and possibly in Ivory Coast and ,ogo in t*e future

2.4 CashewBased on t*e analysis of t*e pro+ect team9 West Africa is t*e second most important producer of Cas*e-uts in t*e -orld (after India$

!igure 4 +orld Cashe# production 5source 7ed 7i(er 9ndustry !, 6


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3 Setting the boundaries for economical sustainability,*e / crops selected for furt*er studies -ere S-eet Sorg*um9 Jatropha curcas 9 Cassava and Cas*e- ,*eplanned bio energy component for t*ese crops is summari


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G

,*e costs for energy carriers9 derived from rene-able sources are determined by t-o ma+or factors= t*ecost of t*e feedstoc8 and t*e cost (comple:ity$ of t*e conversion process or pure plant oil (22O$ and

biodiesel9 t*e conversion processes are relatively simple ,*e ma+ority of t*e costs (more t*an 4&F$ isfeedstoc8 production!ac@uisition costs or et*anol from sugar cane t*e costs of feedstoc8 are more t*an*alf of t*e production costs or et*anol from starc* crops or lignocellulose crops9 feedstoc8 cost is lesst*an *alf of t*e production costs9 because t*e et*anol production process is capital e:tensive and is moreor less effective depending on t*e feedstoc8 source used for fermentation into et*anol (Bindraban %&&G$

eedstoc8 production costs are related strongly to t*e yields ac*ieved for t*e bio energy component of t*efeedstoc8 in t*e field or .atrop*a t*e fruits are collected #e>cortication of t*e fruits leads to t*eproduction of a large volume of fruit coats9 -*ic* can be left in t*e field as mulc* or as compostedmaterial Crus*ing t*e grain results in Crude .atrop*a Oil9 t*e principal energy source from t*e crop and aseedca8e -it* very interesting attributes as a fertili


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be replaced by energy crops It -development for energy crops

!igure & Status of mineral depletion of soi

Energy carriers -ill *ave to compet

-*ic* are eit*er from traditional(diesel9 gasoline and gas$ ,*e c*eae:pensive ,*ere is a relation betneeds (figure 4$

!igure 8 !uel use is related to income in ,

In figure G t*e retail prices for segiven It is very important to realisubsidi


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,*e differences in strategies bet-eeconomic viability of alternative en

systems igure '& clearly s*o-s tprices as a reference9 diesel generata8e into account t*at for most ofand subsidy of mineral energy sourof West African states (Oil and gasc*ange dramatically if all regulatienergy resources is decreased

,*e pressure t*at *ig* internationperiods of relative scarcity or non>into t*e transport sector but also isupply is furt*er complicated by a l

!igure 1* best economical options for ophoto(oltaic 5yello#6 systems 5S. S


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!igure 11 il 5black dots6 and coal 5grey d

It is in t*is setting t*at rene-aenvironmental and social sustainaindirect impacts t*at t*ese developform a very important element for

4 Jatropha curc Jatropha curcas is already in t*e rconsidered as a bio energy crop ,*ampered t*at .atrop*a could beand an economically viable energy

,raditionally .atrop*a plants *aveagainst animal gra


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4.1 rocessing

In figure '% t*e traditional processing of Jatropha curcas is summarioil pressing processes ,*e crude .atrop*a oil (C.O$ can be useddirectly in lo->speed diesel engines eit*er to generate off>grid electricity or to drive tractors ,*e C.O canalso be converted to biodiesel using a trans>esterification process -it* met*anol9 delivering glycerol asby>product ,*e biodiesel produced is suitable for fuel in ve*icles -it* *ig*>speed diesel engines ,*eglycerol can be used in soap production9 cosmetics or for combustion

E:tra bio energy can be obtained -*en t*e crop residues are being fermented to biogas In t*is case fruitcoats and press ca8e are added to ot*er agricultural -aste9 cattle manure and *uman -aste to abio digester ,*e produced gas can be used for coo8ing9 lig*ting and *eating ,*e remaining slurry is ric* inminerals and can be returned to t*e field as fertili


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'0

4.2 !ass and energ" balance

Assuming t*at blac8 fruits are *arvested from t*e .atrop*a trees9 ' ton of fruit delivers ca /%& 8g of fruitcoats and 04& 8g of grain Assuming t*e oil content of t*e grain is around 3/F9 a classical crus*ing process-ould turn ' ton of grain into %5& 8g C.O9 5&& 8g of ca8e and 3& 8g of filter -aste One 8g of C.O can betransformed into ' 8g of biodiesel or ' 1 8g of soap

,*e energy value of t*e various components is given in t*e table belo-

Component nergy (alue forcombustion 5 ?kg6

!ruit coats '' '

)rain 534A oil6 %0 0

il 3G 4

:ress cake 51*A oil6 %0 &

Charcoal 5#ood cake6 %1>3&

4.3 Current projects,*e current pro+ects on .atrop*a are given in figure '3 ,*e estimate of t*e surface of t*e land occupied-it* .atrop*a plants is based on intervie-s -it* operators and t*e information t*at typically9 farmers *aveplanted about 3&F of t*eir farm base in a mi:ed cropping system -it* .atrop*a trees ,*e total surface of

.atrop*a trees is t*erefore estimated at %/9&&& *a ,*is does not ta8e into consideration t*e plants intraditional *edges 2lants -ere raised primarily from locally available seed t*at -as not tested or selectedfor (*ig*$ oil content In some cases9 some first planting -as done -it* seed of selected cultivars Some oft*e pro+ects are also doing agronomy researc* trials eit*er on farm or in collaboration -it* some of t*elocal agricultural researc* centres (see furt*er$ ,*e ma+ority of .atrop*a is co>cultivated -it* food crops orcas* crops In some instances .atrop*a is gro-n as a distinct bloc8 on t*e farm but in most instances9 t*eplants are planted in a *edge pattern As indicated before e:perience teac*es us t*at .atrop*a plants t*atare planted too densely9 are not resulting in economical yields of .atrop*a fruits

Based on t*e suitability maps presented in previous reports9 *alf of t*e pro+ects seem to be in t*e suitable.atrop*a gro-ing areas ,*e ot*er *alf of t*e pro+ects seem to be in areas too dry for optimal production of.atrop*a fruit9 a clear relict of t*e ;7miracle crop syndrome77

ost of t*e pro+ects are based on out>gro-er models some of t*em are plantations Jields per *a per yearvary a lot #ata -ere found to range bet-een '&& 8g!*a for *edges (confirming our observations above$ to3&&& 8g!*a for mature plantations In t*is area .atrop*a is co>cultivated -it* groundnut9 sorg*um9 cotton9mai


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!igure 13 $ocation of Jatropha curcas proj!asoga< & !aso Biocarburant 8 , /7

Selling prices for *arvested grainAssuming / 8g grain is needed to e:crus*ing costs Hno-ing t*at t*e re.atrop*a cannot be used to proComparable subsidies for biodiesel

ost of t*e oil today is being usegenerators as C.O for ca 1&& C A!l

,*e press ca8e is being sold at 1&>5

4.4 #ntermediate oIn ali and Bur8ina aso9 t*e pro+eor less developed agricultural e:teWit* an average planting density.atrop*a ost of t*ese planted *a

In most cases t*ere is already soseedca8e ,*e oil is today primarilt*e local communities to -or8 oncapability and infrastructure to prma8es t*e production of biodiesel f

ects in ali and Burkina !aso. 1 !C 2 9 3 )eres ali Biocarburant 1* Bel#et

sed to be 0&>10 C A!8g but -ent up recenpel ' liter of oil9 t*e feed stoc8 costs for t*e oil itail diesel price in t*is region varies bet-een 1&

uce biodiesel at prices competitive to t*eas an introductory policy9 -ould overcome t*is i

for t*e production of soap t*at is sold at '5

C A!8g for fertili


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'5

)iven t*e current economics of t*e crop and its competitiveness -it* ot*er cas* crops9 t*e pro+ect teambelieves t*at t*e e:tension services need to be intensified in order to bring t*e yields to over 3 tons of grain

per *a (at maturity> 0>1 years after planting$ ,*e yield levels today are in most places belo- '90 tons ofgrain per *a

An important value added component of t*e .atrop*a production c*ain is t*e seedca8e9 -*ic* is used in alot of pro+ects as an organic fertilior cas* crops *as a number ofbenefits for t*e pro+ects and for t*e farming community gro-ing t*e crop

a$ In periods -*ere mineral fertilienergy pro+ects focus too muc* on end use infrastructure development and forget t*e absolutenecessity to *ave a strong agricultural base to t*e pro+ect i8e-ise9 some pro+ects *ave started agriculturalproduction of bio>energy feedstoc8 -it*out t*e (financial$ commitment for t*e investment into do-n>stream processing capabilities Bot* activities need to be developed *and in *and for pro+ects to besuccessful

" S#eet Sorghum in Sierra $eone and %igeriaS-eet Sorg*um is a *ig*>sugar containing variant of Sorg*um *ybrids

ICRISA, *as developed ne- varieties t*at are suitable to gro- in semi>arid tropics and do accumulate *ig*sugar levels in t*e stems9 according to t*e sc*ool of t*oug*t t*at one s*ould ma8e grain sorg*um into as-eet variant9 -*ile maintaining t*e option to also *arvest t*e grain ,*is is completely logical -it*in t*emandate of ICRISA, t*at develops crops for farmers operating in semi arid regions It is *o-ever not yetproven t*at in t*ese areas9 ;7s-eet grain sorg*um77 -ill9 under lo- rainfall patterns9 produce economicallevels of stems and sugar

In addition it *as been demonstrated t*at t*e production of optimal sugar yield in t*e stems is notsync*roni


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'4

!igure 14 $eft sugar content in stems at (arious stages of panicle de(elopment and right #ith or #ithout panicles for (arious(arieties 52*1* )utjar6.

In Brasil dedicated S-eet Sorg*um *ybrids *ave been developed by public and private breeding groups andare tested in co>cultivation sc*emes -it* sugarcane plantations ,*ese sc*emes s*o- a lot of promisebecause s-eet sorg*um can be cultivated on t*e %&F land base -*ic* is left one year fallo- on typicalsugarcane estates In addition t*e timing of t*e s-eet sorg*um *arvest can be sync*ronised -it* t*edo-n>time of sugar mills -*en sugar cane *arvesting season is over In t*is -ay9 sugar> and et*anol plantscan be more optimally used We are investigating t*e potential to develop similar co>cultivation sc*emes inECOWAS countries gro-ing sugarcane and transforming it into et*anol

$.1 rocessing

,*e processing sc*eme of S-eet Sorg*um is given in figure '0 ,*e stems are *arvested and *ave to betransported immediately to t*e processing plants ,*e stems can *ardly be stored -it*out significant loss insugar content In t*e plant '&F -ater is added and t*e sugar ric* +uice is s@uee


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'G

0 tons of -ater is added S@ueeestablis*ed procedure for sugar cane9 for S-eet Sorg*um littlee:perience is at *and in t*e region #ue to t*e similarities of t*e process -it* sugar cane and t*e8no-ledge t*at S-eet Sorg*um stems can be processed in sugar cane mills in Brasil9 it is safe to assumet*at production costs of et*anol from S-eet Sorg*um stems -ill be similar to t*e one for sugar cane?o-ever9 for t*e sugar cane process in t*e region9 it is *ard to produce et*anol against mar8et competitiveprices for butane even if t*ese are not subsidised (#ian8a %&''$ Et*anol production prices from sugar canevary from G ' C A! . to '5 5 C A! .9 -*ile butane retail prices are bet-een 0 0 and '' 5 C A! .)asoline retail prices are *ig*er ('/ ' K %% % C A! .$9 so et*anol from sugar cane may be used as adrop>in transport fuel depending on t*e region It is important to reali


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increase furt*er$ and igeria *as embar8ed on a program to spread t*e 8no-ledge and t*e varietiesenabling suc* yields in t*e country as -ell ,*ere are many cassava varieties eac* *aving t*eir o-n pattern

in time for tuber production ?arvest time can be spread t*roug*out t*e year by varying planting dates andc*oosing t*e rig*t fast> and slo->tuberi50F ,ypically9 ' ton of roots are processed to & 0 tons of rootc*ips -it* a moisture content of '0F ,*e c*ips are grinded and an access of ' 5 tons of -ater is added andmi:ed ,*e slurry is li@uefied -it* steam at '%& oC9 t*en cooled do-n to ca 0& oC for sac*arification andfermentation9 -*ic* releases ca & '1 t CO % ,*e remaining slurry contains 4>'&F et*anol9 -*ic* is distilledCirca & %0 tons of -ater is recycled and around & '1 tons (%&& l9 /144 .$ of et*anol is obtained ,*eremaining % tons of t*ic8 slop contains about 0F solids and can be used for biogas production(2iyac*om8-an9 %&''$ "sing t*is process ca G&F of t*e original caloric value in t*e roots is retained in t*eet*anol 2rocessing ta8es about % 5 .!t feedstoc8 mainly for distillation and drying

%.3 Current projects

igeria *as an internal mar8et demand of 0 billion liters of et*anol for transport fuel and domestic coo8ing,*e igerian et*anol production is not sufficient by far to meet t*is demand In %&'&9 3 companiesimported ''4 1 million liters of crude et*anol mostly from BraOta produced only '0 3 million liters from molasses and cassava (Agbro %&'%$ ,*emassive import of crude et*anol t*us eludes igerian cassava farmers of additional business opportunitiesof feedstoc8 supply Atlantic #istilleries is producing 3&9&&& l from locally sourced cassava feedstoc8 #uraClean *as yet to begin full operations

Evidently9 L 3 41 billion *as already been committed to construct 'G et*anol biorefineries9 '&9&&& units ofmini>refineries and feedstoc8 plantations for t*e production of over % 11 billion liters of fuel grade et*anolper year ive companies already e:ist including t*e % mentioned above -it* a total installed capacity of & %billion liters per year ocations are Bacito9 Sango>Ota9 E8iti9 Bayelsa and agos Anot*er G pro+ects are int*e development p*ase ,-o of t*ese9 located in assara-a and E8iti State9 aim to *ave an integrated bioet*anol refinery and cassava farm ,*e ot*ers -ill use sugar cane9 Sorg*um or imported molasses?o-ever9 t*e entire supply c*ain needs to be re>evaluated because currently bio et*anol from cassava is


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%%

too e:pensive to use for fuel in igeria9 -*ic* *as one of t*e lo-est pump gasoline prices in t*e region(Agboola9 %&''$

)*ana does not produce et*anol from cassava at t*is moment Caltec* Dentures is busy to construct acassava to et*anol plant -it* an initial capacity of 5& t roots!day to yield '&9&&& l et*anol!day t*at *as tobe operational in %&'3 Caltec* gro-s cassava on managed plantations near ?o and estimates it needs +ustover '&&& *a -it* an average yield of %% t!*a per annum to be able to generate enoug* feedstoc8 for t*eet*anol plant ?o-ever9 t*e et*anol -ill not be used for transport fuel because t*e gasoline pump price islo-er t*an t*e et*anol production price and a good regulatory and distribution system to blend gasoline-it* et*anol is lac8ing ,*erefore9 t*e et*anol -ill be used for beverages9 p*armaceutical purposes ande:port (Caltec*$

%.4 #ntermediate observations and conclusions,*ere are very fe- countries in t*e region t*at *ave today a surplus production of cassava over and aboveits food and ot*er industrial needs

,*e first pro+ects of cassava into et*anol production are being developed around central nucleus plantationpro+ects (also *ousing t*e processing and t*e et*anol production plants$ -it* t*e future potential to alsoattract produce from outgro-ers ,*e advantage of t*is model is t*at t*e nucleus farms can function asmodel and demo farms for ne- agricultural tec*nology li8e better varieties or optimi


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%3

from t*e apples li8e +uice and froE (& %F$9 %'F protein9 %/Fcarbo*ydrates9 and t*e rest being -ater9 as* and fibre


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&.3 9ntermediate obser(ations and conclusions

or every ton of cas*e- nuts produced9 about G tons of cas*e- apples are produced ,*is is a very largevolume of potentially interesting biomass to be considered for furt*er processing One of t*e 8ey problems-ill be t*at typically today9 t*e cas*e- nuts and t*e apples are manually separated on farm immediatelyafter *arvesting Organi


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,ppendi- 2 $ist of figures and tables

'iguresigure '= target area for furt*er S-eet Sorg*um study #ar8 green= primary focus area lig*t green=secondary focus area Blac8 dots s*o- e:isting et*anol plants processing sugarcane or cassava 3

igure %= target area for furt*er .atrop*a study #ar8 green= primary focus area lig*t green= secondaryfocus area /

igure 3= ,arget area for furt*er Cassava study #ar8 green= primary focus area pale green secondary focusarea 1

igure /= World Cas*e- production (source= Red River9 Industry9 AO$ 1

igure 0= ,arget area for furt*er Cas*e- study #ar8 green= primary focus area pale green secondary focusarea 5

igure 1= Overvie- of t*e -ay energy carriers are being obtained from various types of bio energy cropsand *o- t*ese carriers are utili

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Ecreee-unido Bioenergy Crops Assessment Third Report

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