Processum – Activity Report 2016

Activity Report 2016

A fantastic year that sets the stage for the future Magnus Hallberg, CEO of Processum

In last year’s activity report I wrote that our cluster was in an excellent position to make the transition from a leading national environment for forest biorefinery development to a leading international one. In summing up the past year, I think we can safely say that that trend is continuing, that conditions now look even better and that, in many respects, we are actually already there.

Proof of this can be found by the inclusion of Processum on a list of 25 excellent examples of sustainable change, which was recently published by the Nordic Council of Ministers. There is also the upsurge in visits by various dignitaries. In addition to the Prime Minister, H.M. the King and the Minister for Rural Affairs, Processum and its member companies have also received visits during the year from state secretaries, senior officials and civil servants with the Ministry of Enterprise and Innovation. We have also been invited to address the Nordic Council of Ministers and the Swedish parliament, the Riksdag, on the subject of bioeconomy and innovation. The fact that our opinion is being sought out at the highest political level puts us in a unique position in terms of influencing future development. This is a position that we have to develop if we want to take maximum advantage of it.

Increased awareness in the international arena of the expertise and infrastructure that our innovation environment can offer is also apparent from the large number of important EU projects that we are involved in. During the year, Processum has received approval for four major EU projects, together with member companies, international industries, institutes and universities. A number of our member companies are also participating in some of Europe’s largest and most interesting biorefinery projects. One of several examples is the EU project ValChem, where SEKAB, together

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with the Finnish forest industry company UPM, is developing and demonstrating processes for the manufacture of green chemical products from forest raw materials.

In addition to the numerous technical biorefinery

concepts that are approaching or have already reached the market, we are also extremely proud to have been granted a three-year transition period for our collaborative VINNVÄXT project, The Biorefinery of the Future, by Vinnova. This was made possible by the enormous support given to us by member companies, academia, incubators, municipalities, regional associations and the county administrative board. This offers us a fantastic opportunity to continue building for the future and developing our region and our cluster. Another gratifying and important development in this area was the announcement about Bio4Energy’s second programme period.

We can therefore feel reassured by the fact that world-leading biorefinery research will continue to be conducted on a large scale by the region’s academic community. The innovation environment is also being strengthened by continued investment by member companies in biorefinery research, and we are delighted by MoRe Research’s recruitment of postdocs and a licentiate within the nanocellulose field.

With the aid of old and new friends at RISE

Bioeconomy, a division within RISE, which Processum joined in 2016, we are further strengthening our cluster by establishing closer ties with important bioeconomy expertise.

All in all, 2016 has been a fantastic year that

sets the stage for the future. The transition to a bioeconomy is coming and forests will play a crucial role. Thanks to this brilliant work, we and our cluster are well equipped to take a leading role in these endeavours. //

PROCESSUM Owned by RISE Research Institutes of Sweden (60 %) and the Processum Interest Association (40 %).

Turnover: MSEK 30 CEO: Magnus Hallberg Number of employees: 19

“This offers us a fantastic opportunity to continue building for the future and developing our region and our cluster.”

Together we are stronger From 2017 Processum will be a part of the RISE Group. The new RISE Bioeconomy division brings together expertise from all the forest’s value chains, and Processum, as a subsidiary, plays a vital part in that, according to the head of the division Birgitta Sundblad.

“Processum, like all the other elements of our division, possesses fantastic cuttingedge expertise within its respective areas – knowledge that it possessed before we became a united group. The main difference now is that through this merger we will complement one another and gain enormous breadth covering the entire field.”

Birgitta Sundblad Head of Division, RISE Bioeconomy

What synergies do you expect from pooling expertise in RISE? “Here we can link together the forest with timber production, pulp production and built environment. The matrix organisation in RISE, comprising six divisions and a number of business and innovation areas which permeate all divisions, means that we can share expertise with each other within the group.”

What will Processum bring to the division?

“We all have important contributions to make to the future we are working for. We operate in one of the world’s most densely-forested areas, with good fibre raw materials which we will use to strengthen Sweden’s competitiveness now and in the future. That is our job at RISE Bioeconomy, and Processum’s skills profile

is the ideal fit. Processum employs advanced processes within biotechnology and organic chemistry in its work on a number of exciting applications, such as single cell protein for fish feed.”

Does Processum’s involvement mean that you will consider taking on new challenges?

“Working within one and the same group means that we can channel resources into areas where they are needed, for instance, when we submit a joint application for EU research funding. This will make our applications stronger, we will have more weight and control, and together we will strengthen our brand. We can simply cooperate instead of competing like we used to do. This form of cooperation is also of value to our customers, who have access to a broader offering through our collaboration within the group.”

What reactions have you encountered following the merger?

“Only positive ones. Within the group we are represented in countless different contexts and the decision to merge has been well received in all the places I’ve visited. Things are looking very bright for the future.” //

SWEDEN’S LARGEST RESEARCH INSTITUTE RISE (Research Institutes of Sweden) has an overarching mandate to collaborate with academia, industry and the public sector on contributing to sustainable growth and greater competitiveness for Swedish companies. During 2016 the former institutes SP, Innventia and Swedish ICT merged to become RISE. Processum is now a subsidiary within the RISE division Bioeconomy, which has 320 employees. The other divisions within RISE are Built Environment, ICT, Bioscience and Materials, Safety and Transport, and Certification. Today, RISE is Sweden’s largest research institute with more than 2,200 employees at 23 sites in Sweden and abroad.

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Interdisciplinary collaboration Processum started as a joint venture with stakeholders in the region. It has since grown and is now an important hub for research in biorefinery processes and products nationally and internationally. Thanks to its expertise and extensive pilot equipment, Processum is able to accept assignments from private clients and also be a partner in large and small research projects, predominantly within the biorefinery field.

Since 2016 Processum has been a part-owned subsidiary of the RISE Group, which is Sweden’s largest research institute. The institutes that make up RISE can collaborate to offer a wide range of expertise, as well as research and development services for more competitive industry and a sustainable society. Here are just some of the assignments Processum is working on in cooperation with RISE and other parties.

ERIFORE

– Realising Europe’s bioeconomy potential Erifore, European Research Infrastructure for Circular Forest Bioeconomy, is a project within Horizon 2020. The aim of the project is to consolidate the expertise and infrastructure that exists in the form of European pilot and demonstration plants for processing different types of biomass. Processum is involved in, among other aspects, a work package on separation and purification processes, as well as a number of large sub-phases. There are a total of thirteen participating organisations from ten different countries.

The project is expected to last 25 months. The project aims to create synergies by bringing together countries and organisations from around Europe. The project will, for example, perform a gap analysis and evaluate interesting value chains within the biorefinery area that are expected to be of importance now and in the future.

“This ties in well with our activities and is entirely in line with our strategy to develop interna­ tional networks,” says Karin Johnson, senior research scientist at Processum. “We have acquired pilot equipment in order to research products from forest raw materials. In this project we are teaming up with other EU projects and facilities that are working on similar things. The project means that we are able to demonstrate our knowledge, skills and the equipment we have at our disposal on site. We increase the awareness of Processum and what we can do.”

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Erifore’s ultimate objective is to create networks and promote collaborations to realise Europe’s full potential when it comes to research into how forest raw materials can be used. All the parties involved have been open and generous with information about existing facilities. The next challenge is to identify business models for how the collaboration could work in practice. The next open meeting takes place in Stockholm in March 2017. Many of the big players have been invited, and Erifore will present an overview of European forest-based research infrastructure.

Business models for alternative infrastructure collaboration arrangements will also be discussed.

Examples of the forest-based bioeconomy research infrastructure in Europe will be provided and assessed, with three specific value chains being evaluated for new bio-based product development. //

KARMA 2020

– Featherlight biomass introduces new opportunities The aim of the Karma 2020 project is to convert feathers into high-value animal feed, or other products, instead of disposing them as waste. Together with fifteen other research organisations and industrial companies from a total of ten countries, Processum is bringing its expertise and resources to the project in the form of pilot equipment.

In 2014 a study was conducted which revealed that, in Europe, a total of three million tonnes of feathers are discarded as waste each year. Currently, the feathers either goes to landfill or are used as low-value animal feed.

The aim of Karma 2020 is to be able to use the feathers for alternative purposes, such as slow release fertilisers, a flameproof coating, bioplastics and bioresins. In order for this to be possible, you have to be able to extract the keratin that is one of the main building blocks in feathers. Processum’s contribution to the project is using its pilot equipment to work on scaling up chemical and biotechnical processes for extracting keratin from feather waste.

The project has been granted funding from the EU totalling EUR 6 million, or approximately SEK 55 million, and will run for three years.

“Karma 2020 will be really exciting and offers a fantastic opportunity to work with a number of European organisations. Having the opportunity to process what is a brand new raw material for us using our pilot equipment is also intriguing. Equipment which otherwise are to develop new products and processes from forest raw materials or from the side streams and residues from the forest industry,” explains Karin Johnson, senior scientist at Processum.

The project begins in January 2017 and will run for three years. //

AGROinLOG

– A project to increase the value of straw Straw is a residual product from agriculture that is in plentiful supply in Europe. It could be used as an alternative raw material to cereals for producing ethanol. Finding profitability in the process is one of the challenges that the Swedish project partners Processum, the Agrifood and Bioscience unit within RISE Bioscience and Materials, SP Agriculture Unit, and Lantmännen will be focusing on in the EU project AGROinLog. There are numerous benefits to be reaped if a profitable bioeconomy process can be developed to increase the value of straw. This involves both developing a process that can efficiently separate the lignin present in straw and finding profitable applications for that lignin.

If a use cannot be found for the lignin that is a residual product of ethanol production from straw, this will be a costly process with a major impact on profitability. Processum is responsible for using a variety of pretreatment methods to extract the lignin and then, with the aid of the HTL process (hydrothermal liquefaction), produce a lignin-based

biooil for biofuel production, for example.

“This is a very exciting project for us,” says Tomas Gustafsson, senior researcher at Processum.

“We normally work with forest raw materials and residue streams from the process industry. Straw is a new raw material for us and we must now employ our processes to produce lignin from straw.”

In order to be able to carry out the work, Processum has built a pilot plant capable of producing biooil using very high pressures and temperatures. The biooil may then be upgraded to biofuels and chemicals, among other products. //

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Vinnova extends The Biorefinery of the Future – proof of our success Processum has been home to The Biorefinery of the Future since 2008. In autumn 2016 the initiative entered a transition period, with an additional three years of funding from Vinnova and the region. A decision that provides possibilities and a starting point for the future.

“This puts us in an excellent position to continue developing our cluster, making it a world-leading environment for forest biorefinery develop­ ment. We receive a tremendous amount of support from the region and the member companies, and we are now beginning to work together on building durable solutions for the innovation environment. The transition to a bioeconomy is just around the corner and our cluster is ready to assume an influential and leading role in the process,” says Magnus Hallberg, CEO of Processum.

frastructure that makes the region incredibly attractive. This, together with great innovative ability, expertise and networks developed within the area, is a crucial factor in being able to achieve the all-important objective of commercialisation. We see Processum serving as an important breakthrough player, broadening the view of what forest raw materials can be used for. Our work is going so well that we are now seeing a number of excellent examples starting to approach commercialisation,” says Moa Eklund, programme manager at Vinnova.

Long-term project

Broad support

Processum was appointed the host for a regional VINNVÄXT initiative, The Biorefinery of the Future, back in 2008. In the eight years since then, The Biorefinery of the Future has put the region firmly on the map as a hub for forest biorefinery development. Extensive research equipment has been installed in Örnsköldsvik and Umeå in order to be able to pursue biorefinery research and innovation projects, from laboratory to demo scale. National and international networks have been established, and over 260 biorefinery projects, including several ground-breaking ones, have been launched since 2008. Some examples of successful projects include single cell protein for fish feed and green liquor sludge for covering mine waste. A number of projects are now app­ roaching commercial introduction.

“Processum has acquired an impressive collection of pilot equipment and a test in-

For Vinnova, the value of the regional initiatives as strong growth engines is more than clear, which is why it has decided to extend The Bio­ refinery of the Future, providing it with SEK 14 million for an additional three years.

“We recognise that a dynamic and power­ ful environment has developed over the years and that Örnsköldsvik, through Processum, has been a pioneer within biorefinery development.

A great deal of success has been achieved in the form of operational results and effects in the innovation system, both regionally and natio­nally.

We have great expectations and believe that there are countless excellent opportunities for Processum to remain an attractive and internationally competitive environment in its field in the future,” says Moa Eklund.

In addition to Vinnova, the County Administrative Board of Västernorrland and

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Moa Eklund, a programme manager at Vinnova, believes that Processum in the future has countless excellent opportunities for remaining an attractive and inter­nationally competitive environment in its field.

Region Västerbotten, as well as the municipalities of Örnsköldsvik, Umeå and Sundsvall, and Processum’s member companies have invested SEK 22 million in the project.

Exciting future The decision by the County Administrative Board of Västernorrland and Vinnova, which have both been involved in supporting Processum throughout the growth initiative, to provide additional funding for the transition period is part of a longterm strategy, and shows tremendous belief in future products based on forest raw materials.

“Processum has been one of the County Administrative Board’s priority activities for many years. It’s no coincidence. Processum is an

important player with links to local industry in Örnsköldsvik, as well as a collaborative partner for research conducted at Mid Sweden University in Sundsvall. There are a host of inte­resting companies emerging from the network around Processum that are leading the way in this field in Sweden. That wasn’t the case a decade ago, so the results we are seeing now are fantastic. The big companies are starting to open their eyes to the sorts of products that can be produced from forest raw materials in the future. This sends out very positive signals, and I believe that the industry structure in our county will be completely different in 15 years’ time, with brand new products available,” says Magnus Karlsson, Director of Operations with the County Administrative Board of Västernorrland. //

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Successful project

that could reach full-scale as early as 2017 On 31 May 2017 a final report will be submitted for the Forest Methanol project. The demonstrator that was installed at Metsä Board in Husum to refine stripper off gases has been in operation and must be evaluated. But although the project has reached its conclusion as far as Processum is concerned, Valmet intends to continue with additional testing during the spring. The objective is commercialisation.

As part of a joint venture between Valmet and Processum, technology was developed to refine methanol from stripper off gases, which resul­ ted in a patent being granted in 2009 and the construction of a laboratory for further deve­lop­­ ment of the method at Iggesund Mill. One of the purposes of the Processum Forest Chemistry project, which was included in Vinnova’s Chal­lenge-Driven Innovation programme, was to study the value chain for production of methanol from the forest industry; that method has now been successfully tested on a pilot scale.

“From a purely operational perspective, it has gone fantastically well. We have put the facility through its paces and it has performed in a stable and safe manner throughout the whole time. Given the level of technology that has been involved, I think that we have achieved the

results expected of the demonstrator,” says Olle Wennberg of Valmet.

What will Valmet do now?

“In order to ensure the quality of the equipment and end product, we want to carry out additio­ nal tests during spring 2017, when we will be modifying some parameters and then conduc­ ting further testing. Our hope is that we will succeed in producing even better methanol.”

How close are you to commercialisation?

“It could happen as early as 2017.”

So when will Valmet build a full-scale facility?

“It’s too early to say at this point, but there is huge interest, particularly in Sweden, in installing this type of purification plant at pulp mills. There are also interested parties outside of Sweden, predominantly among the really big plants. The installation of a purification plant would enable you to produce a greater proportion of methanol and so achieve a reduced investment cost in relation to production.”

“It has gone really well”

A satisfied quintet for Forest Methanol: at the front is Olle Wennberg, Valmet, and from left David Blomberg Saitton, Processum, Jörg Brücher, Holmen, Charlotta Cederström, Valmet, and Hans Sjödin, Metsä Board Husum.

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“When you commission a new facility, you usually encounter a few problems, but this project has gone relatively smoothly. This hasn’t happened by chance, as all the parties involved are professionals in their field, and we have worked really well together,” says David Blomberg Saitton, Group Manager for Organic Chemistry at Processum. The Forest Methanol

“There is huge interest, particularly in Sweden, in installing this type of purification plant at pulp mills.”

project has involved the following partners: Processum, Valmet, Metsä Board Husum, Perstorp, Holmen and SP Process Development.

The demonstrator for refining stripper off gases that was installed at Metsä Board Husum was commissioned at the end of May 2016, and during the project period it has operated for approximately 1,000 hours.

Normally, methanol is manufactured in large-scale processes and the raw materials are natural gas or coal and steam. However, metha­ nol also forms in digesters at sulphate mills, together with a number of other com­pounds that are collected at the top of the digesters. Stripper off gases therefore also contains sulphur com­ po­unds, ammonia, turpentine, water and a number of unidentified substances, which due to their unpleasant odour currently are burned in gas boilers, recovery boilers and lime kilns.

However, combustion results in the emission of oxidised nitrogen compounds or NOx. It is for this reason that pulp mills are interested in refining stripper off gases.

“The pulp industry is under pressure to reduce nitrogen oxide emissions. The methanol we produce contains a lot of ammonium nitrogen, which when burned produces nitrogen oxides; by refining the methanol we can reduce the emissions. Refined methanol can, in the long term, become a profitable residual product that could be sold instead of burned. The price of green methanol and the investment cost determine whether investment in the facility is an interesting prospect or not,” says Hans Sjödin of Metsä Board Sverige. //

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Grant recipients train future chemists Chemistry teachers Marie-Louise Engberg and Stefan Andersson were awarded Processum’s travel grants during the year to enable them to participate in the ‘Experimental chemistry’ course. The course is intended for natural science teachers and aims to give the participants advanced knowledge of experimental modern chemistry.

“We hope with this approach to be able to support our region’s talented chemistry teachers, so that they are able to inspire pupils to become the chemists of the future, who will develop more products based on forest raw materials,” says Magnus Hallberg.

The grants are possible thanks to the local county council’s external environmental award, which Processum won in 2014. The decision was made to use the prize money to award travel grants to chemistry teachers in the region. // Emma Johansson and Magnus Hallberg from Processum present the travel grant to Marie-Louise Engberg.

Updating processum.se It is now even easier to explore and move around Processum’s website and to find relevant information about our areas of expertise and services. Visit the website and read about our expanding range of pilot equipment, interesting research and innovation projects and our ever increasing ability to carry out contract-research assignments. All public projects are reported in a clear manner on processum.se. //

Emanuel Ron from the Faculty of Engineering, LTH, at Lund University.

BioBo works for LTH Carotenoids are a group of molecules that in many cases have an antioxidant effect and could therefore be of commercial interest. Emanuel Ron from the Faculty of Engineering, LTH, at Lund University and Processum’s Biotechnology group have been conducting cultivation tests in one of Processum’s pilot bioreactors, BioBo, involving the bacterium R. marinus in order to see whether it can produce carotenoids.

The project aims to characterise interesting natural products from R. marinus and from the two potential products: carotenoids and exopolysaccharides. Carotenoids are a group of coloured molecules, many of which have an antioxidant effect. These are responsible for the colour of a lot of fruit, including tomatoes and peppers, for example, but they can also be absorbed by animals such as shrimps and flamingos.

Studies have shown that ingesting fruit and vegetables that contain carotenoids reduces the risk of certain types of cancer, which makes the subject of interest to humans, especially as many carotenoids are converted to vitamin A in the body.

Other chemical properties of the carotenoids are already being used by the cosmetic and food industries, among others.

The project with Processum examines the scope for cultivating R. marinus on a residual product from the pulp industry and thus the possibility of producing carotenoids.

Cultivating R. marinus on a 50-litre scale is an interesting and important step in understanding any upscaling problems, as well as measuring how much product it is possible to produce from cultivation on this scale. This is a key aspect in order to evaluate potential commercialisation. //

Bigger and better – increased numbers Processum is always on the lookout for talented individuals who want to be at the forefront of research and development, finding new solutions based on renewable forest raw materials. 2016 was no exception.

During the year Caroline Lindberg replaced Kjell Eriksson, who retired as controller. Within the Organic Chemistry group, Jonna Almqvist and Julia Forsberg were employed as R&D engineers. A number of appointments are expected during 2017. //

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The right mix Using residues from the pulp industry to treat waste from the mining industry has the potential to create valuable environmental benefits. Research and development on green liquor sludge (GLS) as a component in a mixture used to cover mine waste made great strides in 2016. And there are plans to use the mixture during the summer to cover approximately five hectares of mine waste at Näsliden.

GLS is produced during the chemical recovery process at pulp mills. The sludge has so far commonly been used as a construction material in individual dump sites, but is otherwise classed as waste.

The material has a high water retention capacity and exhibits low water permeability. These are critical properties when applying sealing layers (oxygen barriers) to material that is likely to oxidise, such as sulphur-rich waste rock. The aim is for the sealing layer to slow the rate of oxygen transport, as oxygen is transported (diffuses) approximately 8,000 times slower in water than in air.

Processum has worked with Boliden, Ragn-Sells, SCA Obbola, MTC, Domsjö Fabriker, Luleå University of Technology (LTU), Ecoloop, Swerock and Ramböll to develop an effective mixture of GLS and till. Previous projects and PhD studies have shown that mixtures of GLS and till can result in a sealing layer with relatively low water permeability, if it is compacted under optimal conditions.

It is this ability that the researchers are looking to fine-tune.

“Processum is an independent middleman between universities and industry,” says Gunnar Westin, who is responsible for the project within Residual Materials at Processum. “That has proven a strength in projects like these. We have been able to bring together players along the length of the value chain to engage in this long-term technological development. We have opted to compile the knowledge generated as open access guidance making it available to anyone wanting to use this method.”

Watertight protection The first field trial began in summer 2014. A small area was covered with the mixture and certain characteristics, including permeability, have been monitored carefully since then. Once it was shown to work, the trials were scaled up. The latest trial during summer 2016 saw the mixture used to cover an area of approximately 3,000 m2 of mine waste at Näsliden, with equipment adapted for full-scale use. The trial at the pilot site delivered positive results, and during summer 2017 the remaining 4.5 hectares will be covered using the same method.

“The major challenge is getting the logistics to work in a controlled and cost-effective way,” explains Magnus Filipsson, a development engineer for mines/environment at Boliden. “We must have clear instructions, clear implementation control and a recipe that really works. What makes this challenging is that the mixture must be exactly right when it is applied for the sealing layer to work as intended. And as this is a large outdoor area, conditions can change even as the work is being carried out. It may, for example, start to rain and the recipe will then need to be modified.”

Better coverage The sealing layer covering the decommissioned mine at Näsliden is the first time the mixture has been used in a full-scale application.

Boliden, which is responsible for the design of the layers covering the mine waste, is continuing with the project in order to ensure its efficacy and profitability. Magnus Filipsson has only positive views.

“This remains a top priority for us. Although it will require a great deal of work by all those involved to make it perfect, it is still a much better method for sealing a dump site than the ones we used previously.

We will study the data we’ve received from the university and try to find an efficient way to apply the mixture to maintain the right proportion of materials and achieve an even layer that does its job.”

The projects have been running for a number of years and Gunnar Westin at Processum is looking forward to seeing the method used in a full-scale process.

“We have yet to see it through to the end, but I can see several clear indications that we have made excellent progress,” says Gunnar. “For example, Geological Survey of Sweden (SGU) has specified in a public procurement that green liquor sludge must be used in remediation work and has included in its documentation the guidance generated from projects within Processum. It is fantastic that our work will be realised in full scale in the near future at two decommissioned mines. It is not just a product of the drawing board, but something that the mining industry actually wants and needs.” //

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More and better single cell protein One of the most high-profile projects which Processum has worked on has to do with single cell protein. In very simple terms, researchers have developed a method to produce protein from wood that can be used for fish feed. A number of new projects got under way in 2016 involving research into single cell protein.

The hope is to find an effective method of making production profitable and producing as pure a protein as possible.

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There is an intense interest in the technology, both from relevant industries and from the public. The attraction lies in it being a concept that is simple to understand and which has the potential to become very important for both the environment and people.

The advantages of eating trees Producing single cell protein is not a new concept. What is interesting is the fact that researchers here have been able to isolate single cell protein from forest industry side streams, i.e. wood. Primarily, it has to do with protein that can be used for fish feed, but there are hopes that one day it could also be used as food for other animals and even humans.

Single cell protein has numerous advantages. The protein is produced from industrial side streams, can be cultivated regardless of weather, requires less ground utilisation than other sources of protein, and adds no excess nutrients to our ecocycle.

Today, fish on fish farms are often fed either using fishmeal or soya bean meal. Both sources of protein are controversial. Fishmeal production poses an environmental threat, as large quantities of fish are removed from the ocean and ground down to make fishmeal. In many cases, soya bean meal is produced in areas where rainforests would otherwise grow. Single cell protein comprises instead protein-rich microorganisms that can be cultivated in bioreactors. This protects both the ocean fish stocks and the rainforest.

Important that fish are healthy So far single cell protein has only been tested as feed on one species of fish – Tilapia. But research is now looking to find additional applications for the protein. Currently, research is under way into testing the feed on more species of fish and optimising the production process.

“Huge volumes are required in order for single cell protein from residue streams from the forest industry to be profitable. It also has to be ensured that fish eating the protein are healthy, and that anyone then eating the fish cannot taste it,” explains Björn Alriksson, Group Manager for Biotechnology at Processum, and the person responsible for the project. A project was launched during 2016 to test the protein in salmon farming.

Microorganisms on the advance

Björn Alriksson is responsible for the single cell protein project.

Several projects with links to single cell protein were conducted in parallel in 2016. In Örn­skölds­ vik there is a unique setup, with equipment that can cater for everything from laboratory-scale to large demonstration-scale studies, which com­bined with Processum’s expertise in the field attracts stakeholders interested in single cell protein for various purposes. National and inter­

national universities, institutes and companies are collaborating with Processum on single cell protein.

One of the current projects is ‘Forest fish, the fish of the future are growing on trees’.

This is a project in which Vinnova has invested SEK 0.5 million in order to create a new value chain from forest to table. The ultimate objective is to develop a pilot infrastructure that can demonstrate the entire value chain for the circular production system: forest>fish feed>farmed fish>forest fertiliser.

“Because we have developed technology to be able to cultivate microorganisms from residue streams from the forest industry on a large scale, we could produce feed protein for both fish farming and livestock production down the line in Sweden,” says Björn.

Moving towards commercialisation In order to become reality, however, there is a need for efficient and profitable production.

A part in that work is the Bioraff – Mer av trä (More from wood) project, which is a SwedishNorwegian joint venture involving Processum and the Paper and Fibre Research Institute (PFI) in Trondheim. The main aim of the project is to further develop processes and products based on wood and industrial residue streams, including protein production for fish feed, and to carry out a market and economy analysis of the entire value chain, from wood to fish. The development of these new products will strengthen the existing industry, as well as create new companies based on forest raw materials. Another aspect of the project focuses on evaluating and developing the single cell protein to create a microorganism that has a protein content as high or higher than fishmeal, with the hope that it could be used in other food production.

“There is intense pressure from the market to develop sustainable fish feed, and we see great potential in single cell protein. At the end of 2016 our application for the SALMONAID project was granted, which will bring our technology closer to market replication.” //

BACKGROUND IN BRIEF

Research into the protein began as a concept to produce single cell protein using fermentation of a side stream from a biorefinery or pulp mill. It began on a laboratory scale in 2011 and continued with the Microfeed project – an EU/Eurostar project looking into production of single cell protein. The project’s aim was to develop a replacement product for fishmeal. With the aid of BioBo, Processum’s bioreactor, the method was able to be improved and was then scaled up using the Biorefinery Demo Plant. This research has resulted in awards, including the EARTO Innovation Prize in 2014 for the Greenfeed project.

This is the first Swedish research project to have received the award. The reason given was the huge commercial potential of the technology and product.

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Growing interest in cooperation Development is on the up and up, and activities have expanded significantly in recent years. More and more companies are interested in cooperation, which provides access to Processum’s expertise and equipment. Why? “We have seen fantastic development in recent years, and we have had the opportunity to develop infrastructure and critical mass, bringing in personnel within organic chemistry and biotechnology, which gives us unique expertise in forest biorefinery development,” says Magnus Hallberg, CEO of Processum.

“Today, our organic chemistry and biotechnology groups comprise about five researchers each, most of whom have PhD qualifications. Additional recruitment is under way to strengthen both fields.”

Both Swedish and international companies are interested in cooperating with Processum. What have you got that it so attractive?

“In addition to the combination of cutting-edge skills within both biotechnology and organic chemistry, we have also developed a competitive infrastructure in the form of laboratory and pilot equipment. For example, we have a number of bioreactors, ranging from laboratory-scale multi-fermentors up to a 600-litre reactor. The same site is also home to the unique Biorefinery Demo Plant, which is operated by

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SEKAB and can handle as much as ten cubic metres.

We have a strong skills base and advanced equipment within, among other areas, flow chemistry and hydrothermal liquefaction, as well as access to an ATEX-classified laboratory equipped with a number of reactors and columns.

“Yet I would still say that our strongest offering is our network and cluster. In our network of member companies, universities, colleges and within the RISE institutes we can find solutions to most of our customers’ and partners’ problems if we lack capacity to solve them ourselves.”

Why is demand growing?

“I believe that there has been and still is a need for development that Processum is meeting, and that our growth is linked to this growth in demand. Research, development and innovation within the biorefinery field are key to meeting the global climate challenge.

This trend shows no signs of weakening, quite the reverse in fact – demand is growing and becoming more urgent.” //

The importance of being seen There’s no doubt that there is a great deal of interest being shown in the research and development taking place at Processum. In 2016 the number of published articles about our activities was twice that of 2015. And 2015 had also been a record year.

Björn Alriksson and Magnus Hallberg being interviewed by Peter Hansson from radio station P4 Västernorrland.

It isn’t easy to cut through today’s media noise and stand out. That’s what makes the level of interest being shown in sharing news about Processum’s activities so impressive.

A major contributing factor has been a conscious effort on the part of Processum to communicate activities within the cluster.

However, there have also been a number of high-profile visits during the year, including H.M. the King and Prime Minister Stefan Löfven. The combination of visits that cause public interest and a deliberate strategy to increase communication about the research being conducted has proved to be a success.

They are mutually beneficial.

“The visits have, of course, generated a lot of publicity, which helps to raise Processum’s profile as an interesting institute and a hub in a biorefinery cluster with interesting and futureoriented activities,” says Sören Back, Infor­ma­ tion Manager at Processum. “By communicating a lot externally, we are strengthening the image of Processum, which in turn generates publicity and so on.”

It is not only high-profile visits that have attracted media attention, but also press releases and Processum’s newsletters, with more editors finding subjects to focus on in their relevant publications and programmes.

“We appear most in the Swedish media, but our presence in the international trade press is growing, which is something we will be focusing on even more in the future,” continues Sören. “Increased media visibility reflects the fact that we are doing good work and have become an important key player in the bioeconomy arena, which is attracting more attention, making it a popular subject for the press.”

Media visibility brings several advantages.

It can be a useful channel for researchers who want to get a message across. It also helps to put forest-based biorefinery research on the map. Greater knowledge and awareness also increases the chances of funding and interest in continued research within the field. It is therefore particularly pleasing to see that the number of published articles has doubled in just the last year. //

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New pilots and pilot facilities increase capacity Processum’s new pilot facility improves scope for developing and scaling up research processes within the biorefinery field. It is an asset for member companies and other companies, institutes and universities wanting to carry out development work on a variety of scales.

The region is seeing extensive research and development work in the biorefinery field, aimed at improved utilisation of renewable raw materials for a long list of products such as chemicals and fuels. The pilots serve as a test facility for developing new products or improving an existing process. Depending on the focus and scope of a project, one or more of the pilots is used at different stages of the process.

“Since opening we have shared the pilots and premises with MoRe Research,” says Tomas Gustafsson, who is responsible for the organic chemistry pilots. “It has gone really well. As both we and MoRe Research now know that we need room to expand, it was a good opportunity to focus on our respective pilot equipment. We are still both in the same building though, so there is still continued cooperation.”

Necessary for development In 2011, SEK 11 million was invested in building eleven pilot plants in Örnsköldsvik and Umeå.

This was deemed necessary in order to take promising ideas within the biorefinery field from laboratory scale to pilot scale. Since then, the pilot facilities have grown in order to improve capacity and be able to refine the processes.

“The advantage of well-thought-out and diverse pilot equipment is that it is flexible,” says Tomas. “When you combine that with our expertise, research can be conducted on an appropriate scale to get the answers you seek.

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The pilot equipment in its current form enables us to scale up a little more, but if someone wants to produce larger quantities, then the opportunity to do so exists in the Biorefinery Demo Plant.”

Narrows the size gap The so-called pilot facility comprises three parts.

The former welding pit has been converted to a laboratory environment for biotechnology research. The dominant features are the 50 litres bioreactor and the new 600 litres bioreactor. The latter also includes a feedtank and a storage tank, each with a capacity of 500 litres, as well as a CIP system that was also added during 2016. The new reactors constitute two stages in the scaling up of biotechnology research and thus close part of the size gap between the smaller reactor and the Biorefinery Demo Plant, which is also on the site.

For safety’s sake Another feature is the new HTL chamber. This has been designed to enable high-pressure reactions, up to 350 bar, with temperatures up to 450 °C, to be conducted safely. The HTL pilot can be used for direct liquefaction of biomass, for example. Processes can be performed remotely from an adjoining room with a viewing station.

In the neighbouring rooms there is equipment for down stream processing, such as a grinder, centrifuges, a filter press and an evaporator.

“In the coming years Processum will be focusing

Tomas Gustafsson and Julia Forsberg in the ATEX room that was specially built to handle tests presenting a fire hazard.

on working full-time with HTL processes, and so we felt that we had to rebuild and further improve safety.”

Everything has its place

The HTL chamber, designed for high-pressure reactions and high temperatures.

Some of the pilot equipment is still at the previous premises because it is difficult to move.

This includes the pretreatment reactor, which is two storeys high, and the ATEX room, which was specially built to handle tests presenting a fire hazard, for example reactors for chemical synthesis. The ATEX room has, however, been supplemented with, among other equipment, a 50-litre reactor and a Soxhlet extractor that extracts solid material, for example bark, in order to separate out extractive substances. The extractor is connected to the 50-litre reactor.

“There seems to have been a pent-up demand for the Soxhlet extractor,” says Tomas, with a smile. “A lot of people have expressed an interest in wanting to use it. There are a lot of similar smaller pilots, but nothing a little bigger.

This is a 28-litre pilot that we have had to build

ourselves. It provides better answers about contents of extractive substances, as larger volumes make it easier to use a representative amount of biomass in tests.”

Great interest in equipment and expertise Processum has received a lot of praise for its pilot equipment, and more and more parties are showing an interest in using the equipment and expertise gathered here.

“We are along for the whole ride, from concept through tests using the pilot equipment to report preparation. We think the fact that we do hands-on work ourselves using our own equipment and processes increases credibility.

It also takes less time to start up a project, and we can take overall responsibility for projects.

Thanks to our current pilot equipment, we hope to be able to provide not just our member companies, but also other companies and organisations with relevant research data. This strengthens our role as a research hub within the biorefinery field.” //

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The on-site infrastructure now includes

Europes first pilot for CNC The new pilot plant for production of crystalline nanocellulose (CNC) will be ready for commission during the first quarter of 2017. The plant is an important cornerstone in the TinyBTalented project, which begins in 2017 and aims to establish working methods for future application development of crystalline nanocellulose.

In 2015 the decision was made to establish a pilot plant for crystalline nanocellulose in Örnsköldsvik. The pilot plant, which is the result of careful planning during 2016, is being built by Holmen and is based on technology developed

by Melodea, an Israeli company. Both these companies, together with Processum and MoRe Research, are co-owners of the plant, which is the only one of its kind in Europe. Another important contributor is SEKAB, which has played a crucial role in the project during the construction phase, lending its expertise within development and scaling up of biorefinery processes. SEKAB’s premises also house the pilot, and its chemical management and waste streams are linked to the existing Biorefinery Demo Plant operation.

“The Biorefinery Demo Plant is located within our geographic area, where we have extensive and solid experience of experimental production and research on a large scale. This generates huge benefits when developing an efficient pilot plant,” says Emma Johansson, who is Processum’s nanocellulose coordinator.

MoRe Research will play a key role in the pilot’s operation and has recruited postdocs and a licentiate within the field, which further strengthens the environment around the test bed.

The pilot plant, which is expected to be ready during the first quarter of 2017, will

produce 100 kilos of dry material per day.

The plant is the first of its kind in Europe and developments are being followed with interest worldwide – both within the industry and in research circles. There is a great deal of curiosity about the material, which could have an impact in a number of different fields. It is strong and lightweight and, among other features, has exciting optical properties.

“There are a number of applications both within and beyond the forest industry’s traditional business areas where this material could prove interesting. For instance, it could be used in medical contexts to direct drugs to predetermined sites in the body or to introduce brand new properties as a stabiliser in products such as paint and food. It could also be used to manufacture strong yet lightweight building materials with anti-vibration and heat-insulating properties. Bearing in mind the material’s capability, it could also work as a barrier in packaging for carbonated drinks, for example, while we think the optical properties also make it ideal for printed electronics.”

Emma Johansson is also the project manager for the new TinyBTalented project. A test bed with a budget of SEK 8 million over four years that aims to establish working methods for future application development.

The project group, which is headed up by

International cellulose conference

and BioLinX attracted expertise to Örnsköldsvik In November 2016 90 cellulose researchers from industries and universities in eleven countries met to present and discuss the latest findings to come from cellulose research.

The 7th Workshop on Cellulose Regenerated Cellulose and Cellulose Derivatives was organised in Örnsköldsvik by Karlstad University

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and Umeå University, together with Processum and Domsjö Fabriker.

The ambitious programme included around 20 inspiring lectures on a range of different subjects relating to cellulose, and during the breaks there were opportunities to study seven posters on various PhD projects

The pilot is housed at SEKAB’s premises and is linked to the existing Biorefinery Demo Plant operation.

Kristina Elg Christoffersson, Domsjö Fabriker, Ola Sundman, Umeå University, Ulf Germgård, Karlstad University, and Karin Johnson, Processum.

Rough

Fines

Size

The term nanocellulose includes the two variants microfibrillated nanocellulose (CNF) and crystalline nanocellulose (CNC). Microfibrillated nanocellulose comprises both amorphous and crystalline structures, while crystalline nanocellulose comprises solely crystalline structures. Microfibrillated nanocellulose is therefore generally larger than crystalline nanocellulose (see image). While microfibrillated nanocellulose is produced mechanically and has a spaghetti-like appearance, crystalline nanocellulose is produced with the aid of acid and has a structure that resembles a grain of rice. Previous research has focused more on microfibrillated nanocellulose, including at Innventia, which has developed a mobile pilot plant for this field.

MFC

Fine

FACTS | NANOCELLULOSE

CNC

within the cellulose field. Participants also had an opportunity to join a study visit to Processum, MoRe Research and Domsjö Fabriker, which many accepted.

In conjunction with the cellulose conference, there was also a BioLinX Creative Workshop. This was a so-called brokerage event aiming to create stakeholder networks that would help bring bio-based innovations to the market more quickly.

“BioLinX is an EU-funded project. It supports participants in completed and ongoing

Processum, also includes Holmen, Melodea, Mid Sweden University, MoRe Research, Organofuel, RISE Chemistry, Materials and Surfaces, SEKAB, Tetra Pak, and S2 Medical. There is also a stakeholder council associated with the project that represents additional companies and universities. The stakeholder council is part of the efforts made to ensure longevity in the development of crystalline nanocellulose.

“The objective in creating a test bed is to increase the degree of innovation so that research into crystalline nanocellulose more quickly results in a commercial product. It is our assessment that there are applications that can replace several fossil products, which is always the aim of our projects,” concludes Emma. //

research and innovation projects in commer­ cialising ideas and creating contact with knowledge, regional networks, new partners and funding opportunities,” says Jonas Joelsson of Processum.

BioLinX is a unique support and net­ working programme that focuses on parties wanting to commercialise innovations based on raw materials and residue streams from agriculture and forestry. Elements of the support programme are also open to entrepreneurs working on bio-based solutions. //

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in brief

New projects 2016 was, in many respects, a record year for Processum. A number of large EU projects have been approved, as well as Structural Fund projects and the extension of the VINNVÄXT initiative, The Biorefinery of the Future. Processum’s cluster and member companies are taking a keen interest in pursuing development and taking strategic action in multiple areas.

“It has been an incredibly good year. The approved projects offer us an opportunity to consolidate skills and infrastructure within a number of strategically important areas. The extension of VINNVÄXT is the jewel in the crown, giving us a fantastic opportunity to continue developing the cluster and the regional innovation system,” says Magnus Hallberg, CEO of Processum.

Flagship biorefinery – a step closer to a bioeconomy ‘Flaggskepp Bioraffinaderi’ (Flagship Biorefinery) is a feasibility study looking at the possibility of establishing a full-scale biorefinery. A biorefinery that, if realised, would mean an enormous investment, new job opportunities and a significant step towards a sustainable bioeconomy. Such a facility would generate broad production of bioproducts on a large scale and the feasibility study will show to what extent this would be profitable. An additional aim is to identify the ideal set of processes and products at a future biorefinery.

“In order to have an opportunity to realise a project like this, it is necessary to have a broad focus,” stresses Lars Winter, CEO of Domsjö Fabriker. “To be successful, you need both technical expertise and market know-how, which is precisely what the participants in this feasibility study bring to the table. The study’s strength lies in the fact that the parties involved represent the entire value chain, from forest to products, on the global market as well.”

Processum is leading the feasibility study, which is supported by thirteen companies from the forestry, chemical and retail industries. A large portion of the work will be performed by the consulting company Pöyry and preliminary results are expected in summer 2017.

“It has to do with several different product lines aimed at markets where there is more than one active stakeholder.

The primary challenge here is not the technical barriers, but finding the right concept and bringing together all the elements and players who would need to be involved,” says Jonas Joelsson, Research Manager at Processum, and the project manager for the flagship project.

In addition to producing one million tonnes of textile cellulose, examples of potential products include green chemicals, biofuels, protein products, lignosulfonate and biogas. The technical solutions being evaluated are based on established technology and innovations that are close to commercial realisation. //

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Two applications heading for full-scale implementation Paper Chain is a two-part project that will run for four years. The main focus of the project is developing a process for production of the cellulose ether EHEC (Bermocoll) based on renewable raw materials from a mill’s side streams and dissolving cellulose. Bermocoll is used as a thickener in paints and is manufactured from cellulose and ethyl chloride, among other ingredients. The project will examine the entire production chain from the mill’s side streams right through to production of Bermocoll, with emphasis on the chemical synthesis of ethyl chloride from renewable ethanol only.

The local companies Domsjö Fabriker, SEKAB and AkzoNobel are collaborating with Processum on the project, which will get under way in mid-2017.

“There is a keen desire for the process to achieve full-scale implementation if the project goes well,” says David Blomberg Saitton, Group Manager for Organic Chemistry at Processum.

Part two looks at the potential applications for green liquor sludge (a residual product from the chemical recovery process at pulp mills) as a sealing layer for covering mine waste. Green liquor sludge has a high water retention capacity and acts as an oxygen barrier, which prevents metals leaching out.

A product not previously exploited to its full potential could now be used as something valuable – and implementation has already progressed some way.

“We have already begun commercialisation of this product. The project will run in parallel with efforts to encourage market participants to implement the technology in their own operation,” says Gunnar Westin, the project manager at Processum. // The new bioreactor was unveiled by Magnus Hallberg and christened BioClas during the inauguration of the new pilot chamber.

Progress in work towards a more sustainable society Bioraff 2020 is a three-year research project focusing on the development and application of products from renewable forest raw materials. One element of the project involves the expansion of Processum’s extensive pilot equipment with new functionality, because access to relevant equipment is vital to making new products a reality. The new multi-fermentor will improve conditions for conducting biotechnical experiments involving multiple tests. Up to twelve tests can be conducted in parallel, which improves the quality of results and saves time and money.

Another element involves collaboration with the company C-Green and their technology for HTC treatment of biomaterials. C-Green has opted to install its pilot equipment at Processum, where it forms part of the pilot facility in the same way as any other equipment. The aim of the technology is to increase the value of residue streams. There is considerable demand for HTC treatment and so tests can be conducted involving a wide range of organisations.

The results of Bioraff 2020 will take us a step closer to a more sustainable society. This project is expected to contribute to an increased number of technologies achieving full industrialscale production in the region within five to ten years. //

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Processum and Domsjö Development Area – a popular attraction A lot of people are interested in the innovative development of a forest-based biorefinery that is taking place in Örnsköldsvik. During 2016 Processum welcomed a number of ministers and other representatives of the Swedish government and authorities on visits.

His Majesty the King also visited the area to learn more about how a biorefinery works in practice.

It is not unusual for students and universities to take the opportunity to visit the Domsjö Development Area to learn more about the technology of the future and a biorefinery based on sustainable forestry. In recent years countless decision-makers have also visited Processum and its member companies. The area is a popular destination for such visitors because of the number of local companies involved in largescale production based on forest raw materials and companies conducting cutting-edge research and innovation.

“The Domsjö Development Area and the Norrland coast constitute a unique environment, where green chemicals, fuels and materials are already being produced, and where new biorefinery processes are being developed in close cooperation with world-leading industries, research companies, research institutes and academia. We are proud to be able to show this off to His Majesty the King, the Prime Minister and the Minister for Rural Affairs,” says Magnus Hallberg, CEO of Processum.

Royal visit His Majesty the King was given a guided tour of the Domsjö Development Park during his visit in September. Lars Winter, CEO of Domsjö Fabriker, gave a presentation about Domsjö Fabriker’s evolution from a traditional pulp mill to a modern biorefinery. He also provided information about products that originate from sustainable forestry, products that can be found in, among other items, viscose clothing, medical tablets and personal hygiene products.

Processum, together with four member companies – Domsjö Fabriker, SEKAB, MoRe Research and AkzoNobel, demonstrated how a forest-based biorefinery can be the starting point for the transition to a bioeconomy. This was achie-

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ved by showing examples of some of the bio­ refinery products and technologies we work with.

The visit focused on a sustainable forest industry and future opportunities for refining raw materials.

Fascinated ministers Sven-Erik Bucht, Sweden’s Minister for Rural Affairs, accompanied His Majesty the King on his visit, but has also visited Processum in the company of Prime Minister Stefan Löfven. They both showed enormous interest in the work being conducted here.

Karin Johnson explains Processum’s activities to the Minister for Rural Affairs Sven-Erik Bucht and H.M. King Carl XVI Gustaf. Riksdag member Eva Sonidsson, Prime Minister Stefan Löfven and the Minister for Rural Affairs Sven-Erik Bucht are impressed by the quality of the viscose thread produced using Domsjö Fabriker’s cellulose.

“It is fantastic that the activities being conducted in this region are attracting so much attention from the government,” says Magnus Hallberg.

“In a little over a year we have received visits from the Prime Minister and the Ministers for Enterprise, Rural Affairs, Energy and Strategic Development. This is a great acknowledgement, that we are making good progress and that the government shares our view that forests and the biorefinery concept are key to securing future jobs and sustainable development.”

Sven-Erik Bucht, the Minister for Rural Affairs, visited Processum back in March. He was taken on a guided tour of the Biorefinery Demo Plant by Thore Lindgren of SEKAB. The plant enables successful processes to be scaled up under factory-like conditions.

State Secretary Elisabeth Backteman from the Ministry of Enterprise and Innovation, as well as a number of members of the Riksdag, have visited Processum and the cluster to get more information about the opportunities that exist within the biorefinery field. The Ministry of Enterprise and Innovation is assigned to develop a national bioeconomy strategy for Sweden. The parties responsible for developing

this strategy chose, as an initial stage in the pro­ cess, to make a two-day visit to the area, organi­sed

by Processum.

In the political spotlight Each and every visit is an opportunity to convey knowledge and highlight the action needed to enable developed technologies to be used in fullscale industrial facilities and renewable forestbased products to compete with today’s fossil pro­ducts. It is therefore an extremely positive out­come to have representatives of parliamentary parties visit Processum and the member compa­ nies. Although the companies are technically capable of achieving great things political support and commitment are needed if the results of our activities are to be realised in the form of products and services.

“It is clear that a bioeconomy and the role of forests are right up there on the agenda now, and that awareness is increasing amongst politicians and civil servants,” says Magnus Hallberg after the visits. “It is wonderful to be able to show the potential that exists for realising a bioeconomy based on forest raw materials.” //

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RISE Processum AB Box 70, SE-891 22 ร rnskรถldsvik, Sweden Tel.: +46 (0)10-516 67 50 | info@processum.se first name.surname@processum.se | www.processum.se