Kalundborg Bioenergy
Turning insulin waste into energy
In co-operation with Ørsted, Bigadan has established a full-scale biogas plant that we now operate. The plant handles waste products from the insulin and enzyme production at Novo Nordisk and Novozymes.
![Inside Novo Nordisk factory](https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/novo.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=500&q=90&w=400&s=770342b923c5697cf2f43186e8610b1d 400w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/novo.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=750&q=90&w=600&s=ba4fda80060d95e86db71166964fdfca 600w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/novo.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1000&q=90&w=800&s=b4d9304476d4d095d2662530acbfa0fa 800w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/novo.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1250&q=90&w=1000&s=dd8dd0cd241362536c26dae1e084a956 1000w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/novo.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1500&q=90&w=1200&s=5dbdb3a1b9edbd5bfa84d00ea086ddeb 1200w)
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Bigadan processes yeast cream from Novozymes annually 300.000 tons
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Processing yeast cream cover the heating consumption annually 15.000 households
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The production equates to a total annual reduction of CO2 72.000 tons
A meaningful partnership
Bigadan procures organic by-products from Novo Nordisk and Novozymes' insulin and enzyme production. These by-products consist of yeast cells and biomass fra biotech production, the medium in which insulin and enzyme is cultivated. Once the fermentation process concludes and the insulin and enzyme are extracted, this residual 'yeast cream' is thermally treated for safe reuse. This transforms it into biogas, which is upgraded for the gas network, and into high-quality fertilizer for local agriculture. Annually, Bigadan processes about 300,000 tons of biomass from Novo Nordisk and Novozymes.
![Pipelines on biogas plant](https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/3kalundborg.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=500&q=90&w=400&s=f3db21be04fe1cbc3a2bdbf92d12004d 400w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/3kalundborg.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=750&q=90&w=600&s=8864c20cfc99add2c76bd98579af4df6 600w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/3kalundborg.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1000&q=90&w=800&s=065fbc0f37f17a05679602eef5470a95 800w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/3kalundborg.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1250&q=90&w=1000&s=c2ded73ba1c431922134591b40bbe832 1000w, https://bigadan-web.imgix.net/images/Case-Novo-Nordisk/3kalundborg.png?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=1500&q=90&w=1200&s=d1779e3225fe9f4a4074f0eecfcf04f4 1200w)
From the factories to the farmers
The journey from managing and bio-digesting Novo Nordisk and Novozymes' organic residuals to converting yeast cream and biomass fra biotech production into a farmer's field fertilizer epitomizes the close-knit collaboration between Bigadan, Novo Nordisk, and local farmers.
In addition to the 300,000 tons of yeast cream and biomass fra biotech production handled by Bigadan yearly, approximately 50,000 tons of other biomass, including animal glycerin, are incorporated. Collectively, they capitalize on the equivalent of 30 million cubic meters of gas and fertilizer for 10,000 hectares of land.
Overcoming the challenges
Back in 2015, Bigadan tested the gas potential of fermentation residues (yeast cream and biomass fra biotech production) from Novo Nordisk and Novozymes at a biogas pilot facility. Handling yeast cream presented challenges due to its cumbersome nature and strict safety requirements. However, the results were promising, leading to the construction of a full-scale biogas plant and the establishment of a distribution channel for the fertilizer component.
This recycling of the by-product has notably resulted in a series of fertilizer products. The value of reusing this residue lies particularly in its nutrient content and plant availability, superior to standard livestock manure
![Tanks from biogas Plant](https://bigadan-web.imgix.net/images/General/Kalundborg.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=400&q=90&w=600&s=329db1f9a67eea9e20e2fcfe5ccd8baa 600w, https://bigadan-web.imgix.net/images/General/Kalundborg.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=533&q=90&w=800&s=9cf44784be11ae61a549c9e638233cd4 800w, https://bigadan-web.imgix.net/images/General/Kalundborg.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=667&q=90&w=1000&s=fb84968550f5c03ba763090276047481 1000w, https://bigadan-web.imgix.net/images/General/Kalundborg.jpg?auto=compress%2Cformat&crop=focalpoint&cs=srgb&fit=crop&fp-x=0.5&fp-y=0.5&h=800&q=90&w=1200&s=89beec93ede86d370f75ceccd61aada7 1200w)
“Sustainability is part of our DNA. Now, we are also starting to use biomass for large-scale biogas production. It's a double win for recycling by-products to benefit the environment, a prime example of true circular economy”
Jesper Haugaard
Vice President, Novozymes production in Europe and Denmark
“What we do in Denmark, utilizing biomass in new ways and in novel configurations, resonates globally as the circular economy gains traction”
Anders Schou
Product Chief, Kalundborg Bioenergi
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