Essential to all goals of the project is the access of residual biomass sources containing sufficient amount of fermentable sugars. An area search for biomass sources in the vicinity of Kanteleen Voima’s planned NordFuel production facility in Finland could identify five suitable subtypes of biomass and relevant amounts of these were shipped to Sekab’s Biorefinery Demonstration Plant (BDP) in Sweden.
Sugar analysis of the various biomass subtypes residues show a clear preference for specific subtypes containing lower amounts of branches, tops, and bark. Thus, by selection of high sugar yielding subtypes substantial higher concentrations of fermentable sugars are achievable.
Continuous pre-treatment and hydrolysis experiments with durations exceeding 2 weeks based on the CelluAPP® technology were performed of each subtype and relevant combinations thereby demonstrating actual sugar content at industrial relevant enzyme dosage. The resulting sugar solutions were subsequently shipped to Terranol in Denmark for determination of continuous fermentation conditions including determination of the complete package of micro- and macronutrients reaching the targeted ethanol yield by employing the novel CoRyFee fermentation concept.
The accumulated results and experience from the pre-treatment/hydrolysis and fermentation experiments allowed the partners to prepare, execute, and analyse a trial in near-industrial scale in the BDP. The full technology package for biomass into ethanol processing was demonstrated, verified as well as backwards verified. The results from performed trials showed that the CoRyFee Technology performance was above that of conventional batch and fed-batch fermentation processes and the set targets regarding yeast consumption, productivity, and ethanol concentration were all reached or exceeded in relation to set project goals. Furthermore, the concepts superiority to operate for a long period of time was confirmed when the continuous setting was maintained without bacterial infections, technical or mechanical failures for the duration of 14 days of continuous operation.
It can be established that the CoRyFee Technology is a fast and stable concept offering a high revenue opportunity allowing cellulosic ethanol plants to operate at full capacity fast enough after permitting and construction, thereby mitigating the most important risk of all, “the Valley of Death”.
Kanteleen Voima’s Nordfuel biorefinery in Haapavesi has received the necessary environmental permits and an EU investment approval to support construction of the plant. The biorefinery utilizes existing buildings and infrastructure and the site preparation is scheduled for completion by the end of 2022.
