In drawing up this manual, **Chemtex Italia, Alasia Franco Vivai**  and **For Energy**  undertake to encourage rapid development of the cultivation of Arun
do donax (giant cane) for the production of biomass intended for conversion into second-generation ethanol. The aim is to provide support for small, medium and large-scale farmers wishing to learn the most up-to-date techniques for growing Arundo donax, by making available to them, concisely and clearly, the results of our experience and expe
rimental activities conducted in recent years. We have decided to divide this manual into four sections: **> The project** Illustrating the goals pursued by the Arundo donax growers for conversion to 2nd generation ethanol. **> Research and selection** Providing technical and scientific infor
mation on the giant cane and the process of selecting the best genotypes. **> Crop management** Describing the basic technique for ma
naging giant cane crops, from rhizomes for the preparation of propagules to har
vesting. **> The partners** Illustrating the activities conducted by every company that has undertaken this initiative. 

# introduction

# the ProjectThe idea to implement this project aro
- se from the M&G Group’s belief that biofuels can contribute decisively both to reducing greenhouse gases and cur
- bing dependence on imported fossil fuels. In order to trigger off this virtuous cir
- cle, a number of fundamental condi
- tions should be met: 1. **Sustainability for farmers** : farmers must be able to grow this biomass even on marginal fields, obtaining a fair in
- come and profiting from a net impro
- vement in terms of water consumption, use of fertilizers and plant protection products. 2. **The price** of the biomass meeting requirement 1 must be such as to make the resulting biofuel (in this case etha
- nol) competitive in comparison with traditional fuels (petrol and Diesel fuel). 3. **The technology** of bio-ethanol pro
- duction must be fully efficient so as to ensure profit on the free market, even without subsidies. Based on these pre-requisites, the M&G Group has demonstrated the fe
- asibility of the processing cycle under laboratory conditions by completing a 120 million euro research programme on ethanol from biomass (PRO.ESA Bio-ethanol production from ligno
- cellulosic biomass Pre-treatment and hydrolysis). 

## The Project Clean fuel from natureIn order to identify the ideal crop, va
- rious plants have been tested from the agronomic standpoint, considering both yield per hectare and minimization of agronomic inputs. In this respect, the giant cane (Arundo donax L.) proved to offer a very high biomass potential yield per hectare (up to 50 tons/hecta
- re), resulting in an ethanol output of over 10 tons per hectare. **Lab tests** , in particular on the bio
- mass treatment (experimental enzy
- matic hydrolysis and fermentation), have confirmed **total ethanol yields of over 95%**  , thereby making the process competitive even in comparison with traditional fuels. The data collected, both from on-farm agronomic experiments and experi
- mental lab tests, constitute the basis for the management of both the growing cycle as well as the production pro
- cess. In 2009 the M&G Group will collect data on the pilot plants, some already installed, others in completion phase, and according to programme will begin, in **2010** , construction of the first demo/industrial plant powered by breakthrough technology. The aim will be to process 160,000 tons per year of (anhydrous) Arundo donax, correspon
- ding to around 3,500-4,000 hectares. It is therefore fundamental to create an agro-industrial supply chain close to the processing site, in order to ensure a consistent and constant biomass sup
- ply over time. 

## The Project Clean fuel from nature 

## The Project Clean fuel from nature The M&G Group has asked Alasia Franco Vivai, located in Savigliano (Cuneo), to conduct a study on va
- rious Arundo donax varieties aimed at selecting the best ecotypes/origins and their propagation. Alasia Franco Vivai will therefore be responsible for growing and supplying the rhizomes with which to set up the new plantations in the future. In addition, ForEnergy, a company lo
- cated in Vigevano (Pavia), will handle farming and supply contracts, as well as logistic services and shipment to the production plant.

# Research and selectionThe Giant cane ( Arundo donax L. ) is a perennial graminaceous plant. Its area of origin stretches from the Mediterra
nean countries to the Middle East and even India. It is found in Italy from the hillside areas to the coast. It is the largest cane found in Europe, generally reaching a height of 6 metres. In ideal conditions it can even grow over 10 m in a year, with hollow stemshaving a diameter of 2-3 cm. The greygreen lanceolate leaves are alternate, 30-60 cm long and 2-6 cm wide.This variety blossoms in SeptemberOctober, producing sterile, spindleshaped, plume-like flower-heads, 40- 60 cm long, with colours from pale green to violet. Propagation is routinely done by plan
ting rhizomes (Picture 1) or parts of the stem, which readily establish. Picture 1 Giant cane rhizome

Picture 2 Giant cane plantation 

# The arundo donax varieties Research and selection Clean fuel from nature

## Research and selection Clean fuel fromnature Careful research and selection activi
ties have been carried out at the **Alasia Franco Vivai**  company, in collabo
ration with **Chemtex Italia** , aimed at identifying the best origins. Other di
scriminating factors taken into consi
deration, apart from productivity, were the energy inputs needed to grow the cane. This will ensure the farmers gre
ater freedom from price fluctuations of fertilizers, plant protection products and fuels, widely used for traditional crops, and imply a milder environmen
tal impact. It was shown by extensive cultivation that, as is also stated in the bibliogra
phy, it is practically impossible to ob
tain reproduction by gamic tactics, that is to say by the union of two inflore
scences (Picture 3). Picture 3 Controlled breeding tests on plumes of Arundo donax L. 

## Genetic improvement of the giant cane As a part of this qualitative selection process, Alasia Franco Vivai collected 89 phenotypes of Arundo Donax har
vested in the entire area where it grows – Southern Europe, North Africa and South China – and planted them in a number of plots to compare the selec
ted varieties (Picture 4) and to assess their morphological and physiological features (Pictures 5, 6 and 7). Picture 4 Comparative plots of the collected phenotypes

Picture 5 Recording the heights of the different phenotypes 

## Research and selection Clean fuel from nature

## Research and selection Clean fuel fromnature Results were recorded in terms ofheight, phenology, growth, droughtresistance, growth rate, resistance to adverse biotic and abiotic conditions, alcohol output and yields.

Picture 6 Measurements on shoots from the same phenotype

Picture 7 Bud break in Arundo plots with comparisons betwe en several phenotypes, showing the variability between different origins belonging to the same va riety. Ecotypes with differing phenology are used to enable harvesting at different times. Careful selection work led to the iden
tification of highly productive varie
ties, characterized by a remarkable growth rate, able to ensure very high yields reaching 40 tons of dry matter per hectare per year. Picture 8 shows a selected genotype (R2F1, two years’ root and one year’s growth) which has reached a height of 6-7 metres in a single vegetative sea
son.

Picture 8 

## Research and selection Clean fuel from nature

# Crop management

## Crop management Clean fuel from nature To allow rapid and effective germina
tion, it is advisable to transplant the rhizomes. It is necessary to use por
tions of rhizomes at least 8 cm long, containing one or more buds, even if dormant. For this purpose the propagules are produced in special rhizome beds from which, one year after sowing, dense clusters of rhizomes are uprooted (Pic
ture 9), cut into fragments of about 8 x 4 cm (Picture 10) and used in the ac
tual plantations. 

# Preparing the rhizomes

Picture 9 Cluster of rhizomes uprooted for selection

## Crop management Clean fuel fromnature Between 2007 and 2009 numerous ex
perimental plantations were set up in fields in Savigliano in the Province of Cuneo (Picture 11) and Tortona in the Province of Alessandria.

Picture 10 Rhizome before planting Picture 11 Experimental plot 

## Crop management Clean fuel from nature Preparing the sowing bed is an impor
tant preliminary operation to ensure that the rhizomes take well. In highly calcareous and clayey soils only, subsoiling is necessary (70-80 cm), followed by shallow ploughing (30 cm). Subsoiling is indispensable to break up any hardpans or more compact la
yers that may be caused by the repe
ated passage of farm machinery or by alluvial sediments never removed in previous years. Ploughing (Picture 12) needs to be car
ried out to a depth of 30 cm. On rather sandy soils it is advisable to carry it out just before transplanting the rhizomes, so that any residual weeds are buried and the soil can stay clear as long as possible. If the soil tends to be clayey, ploughing is to be done in the autumn before tran
splanting, since weather conditions (frost, sun, heat fluctuations etc.) have a significant influence on the structural improvement of the soil. 

# Preparing the sowing beds

Picture 12 Ploughing to a depth of 30 cm

## Crop management Clean fuel fromnature After ploughing it is fundamental for the soil to be carefully smoothed by harrowing it two or more times with a trailed or rotary harrow (Picture 13). The purpose of this process, which should preferably be done immedia
tely before transplanting, is to prepare the soil for planting the rhizomes. This smoothing process avoids the for
mation of excessively large lumps of earth and consequently the accumu
lation of air near the rhizomes, which would hinder root emission, potential
ly hampering germination and deve
lopment of the epigeous part.

Picture 13 Smoothing the soil 

## Crop management Clean fuel from nature The rhizomes are planted with a modi
fied transplanting machine (Picture 14) which lays them at a depth of 10 cm in such a way that they are completely covered by the soil. This operation is performed by companies managed by ForEnergy. It is advisable to foresee a containment area around the field of about 3 m, that should be cleared with a disc harrow at least once a year (Picture 15). It is advisable to avoid planting when the soil is frozen. 

# Transplanting and first year care

Picture 14 Sowing the rhizomes

Picture 15 Containment area

## Crop management Clean fuel fromnature After transplanting the rhizomes it is necessary to apply a pre-emergence (anti-germination) herbicide, distribu
ted by a boom sprayer. The herbicides allowed in the post-planting phase are Oxadiazon, Pendimethalin and Oxi
fluorfen in the concentrations shown on the label.If planting is done later than midMarch, this treatment is to be applied immediately after transplanting. These treatments must in any case be applied before emergence of the sho
ots (Picture 16).
Picture 16 Anti-germination weeding 

## Crop management Clean fuel from nature Between the end of April and the be
ginning of May the shoots begin to emerge from the soil (Picture 17). By late May the rhizome shows 2-3 de
veloped buds (Picture 18) while the epigeous part reaches a height varying between 40 and 60 cm.

Picture 17 Shoot emerging after sowing

Picture 18 Rhizome vegetating (May of first year)

## Crop management Clean fuel fromnature At the beginning of June of the first vegetative season the plants reach a height of about 1 metre (Picture 19). In the first year only, it is possible to limit weeds by using a spring tooth harrow between the lines (Picture 20). By the end of June ground coverage is prac
tically complete (Picture 21). At this stage the root structures reach a depth of 1.3 metres (Pictures 22 and 23).

Picture 19 Growth in the month of June of the 1st year
Picture 20 Harrowing 

## Crop management Clean fuel from nature

Picture 21 Growth at the end of June (1st year)

Picture 22 The root structure has reached a depth of 1.3 metres Picture 23 Detail of the root structure

## Crop management Clean fuel fromnature After the winter cutback the regrowth of the canes is very vigorous and from the second vegetative season the num
ber of shoots per stem increases signi
ficantly (Picture 24). Picture 24 Vegetative regrowth at the beginning of the 2nd year (sucker growth) 

# 2nd year care Crop management Clean fuel from nature From this stage onwards, management of the site no longer calls for any spe
cial attention since the density of the shoots resulting from rapid growth (a feature taken into consideration in ge
notype selection) and the virtual ab
sence of pests make for a very rustic kind of crop (Pictures 25 and 26).

Picture 26 July of the 2nd year on a semi-hilly soil Picture 25 Plantation seen from inside

## Crop management Clean fuel fromnature By July of the second year the root structure of the Arundo stump has rea
ched a depth of 2.2 m (Pictures 27 and 28). Picture 27 The root structure has already reached the water table 

## Crop management Clean fuel from nature By penetrating the soil to such a depth, the Arundo donax root structure is able to reach the water table and the nitra
tes available in it. For this reason irri
gation and additional use of chemical fertilizers are not required, resulting in significant environmental benefits and a substantial reduction in management costs.

Picture 28 The stump roots reach a depth of over 2 m

250 200 150 100

50

0

0,25

0, 2 0,15

0, 1 0,05 0 **Use of water**

**Use of nitrogen** Arundo donax Sorghum fibre Corn biomass Corn grain**m3/ton d.m. Kg N/ton d.m.** 

Arundo donax Sorghum fibre Corn biomass Corn grain

## Crop management Clean fuel fromnature At the end of the second vegetative se
ason, if managed correctly, the canes should reach a height of 6-7 metres with an average output varying, ac
cording to the phenotypes and the pre
vailing conditions, from 30 to 50 Tss/ hectare/year (Picture 29).

Picture 29 Plantation in autumn before harvesting 

## Crop management Clean fuel from nature The harvest is fully-mechanized (Pic
ture 30) and performed by suitably equipped sub-contractors managed by ForEnergy. The harvesting period ex
tends for 11 months and stops in De
cember. By correct planning of the harvesting calendars, 12 harvests can be made in 10 productive years. The selected genotypes of giant cane can reach a productivity per hectare of 40 t/ss/year (80 t/green/year). The first cut must be made at a height no greater than 10 cm from the ground. Canes harvested at a distance of over 15 km from the biorefinery must be taken directly to the biorefinery or to a collection point accessible to trailer trucks or semi-trailer trucks for loa
ding and subsequent transport. If they are harvested within a range of 15, km they are delivered directly by farm trailers. An Arundo donax plantation may last many years, theoretically for ever, gi
ven that the plant is a perennial; ho
wever the bibliographical data refer to observations made over a maximum of 10 years, which is also the reference period used by Chemtex and its part
ners. 

# Harvesting

Picture 30 Mechanized harvestingOn the day of the last harvest, a herbi
cide (glyphosate) should be applied on the freshly cut surface. This operation allows the herbicide to be absorbed immediately by the plant and has a 95% kill rate. A few days af
ter this treatment the rhizomes need to be removed with an excavator similar to a beet-harvester. 

# Removal at the end of the cycle

Picture 31 Growth at 15th July of Arundo donax coppiced at different times. Plot coppiced at the beginning of March Plot coppiced in mid June 

## Crop management Clean fuel from nature

# the Partners**Chemtex Italia, Gruppo M&G** The M&G Group is a family-run mul
- tinational company with headquarters at Tortona (Alessandria). M&G is the world leader in PET pro
- duction for packaging and the second chemical manufacturer in Italy thanks to 2,400 employees (30% of the staff consists of engineers and researchers), 16 companies located in 4 continents, an output of 1.7 million tons of poly
- mers and a $2,600 million turnover. Since 2004, also following the acqui
- sition of Chemtex Int. Inc., the M&G Group has grown in the field of engi
- neering, supply and production of po
-lyesters (fibres and polymers), petrolchemical products, special chemical products and bio-fuels, extending its presence into China and India. **ForEnergy srl** ForEnergy S.r.l., with head offices in Vigevano (Pavia), plays a leading role in Italy in the sector of cellulosic bio
- fuels, relying on its legacy as a pioneer in this field and on its over 3,000 hec
- tares of dedicated ligneocellulosic bio
- mass currently under management. ForEnergy s.r.l. seeks to exchange ex
- perience, develop group synergies and identify new partners, while investing consistently in its strategy dedicated to the development of biofuel produc
- tion and supply chains on a variety of scales, from more local ones aimed at developing Energy Farms and local energy plans, to broader ones to sup
- port larger energy production plants by always focusing to the best of its abili
- ty on short supply chains. In this way ForEnergy intends to act as a fundamental interface between far
- mers and manufacturers with a view to promoting greater profitability for farms and the long-awaited take-off of the biofuel sector. 

## the Partners Clean fuel fromnature

CHEMTEX ALIA IT 

## the Partners Clean fuel from nature

## the Partners Clean fuel from nature

**Italian Bio Product S.p.A.** ITALIAN BIO PRODUCTS S.P.A. will work in the ex-Teksid area at Cre
sentino (Vercelli) to produce bio-etha
nol from biomass energy crops: corn straw, rice straw and Arundo donax (giant cane). The factory, which requires an overall investment of 110 million euro, will produce 40,000 tons of bio-ethanol per year and demonstrate, for the first time on an industrial scale, the validity of this innovative technological option. 

## the Partners Clean fuel fromnature

**Alasia Franco Vivai** Alasia Franco Vivai s.s. of Savigliano (Cuneo) was the first company in Italy to set up a biofuel supply chain based on dedicated crops for vegetable bio
masses. Since 1998, in fact, it has worked in close collaboration with the major players in the sector, such as farmers and manufacturers, becoming a funda
mental point of reference for all those working in the field of short rotation crops. The main areas of expertise at Alasia Franco Vivai are the genetic improve
ment of fast-growing varieties for bio
mass plantations and the production of the vegetable material necessary to set up these same plantations.