Hardwood Research Initiative

Transcription

1 Hardwood Research Initiative Isabelle Duchesne, Ph.D. Francis Fournier, F. Eng. Ontario Hardwood Management Tour, October 19 21, 2010 Mattawa & Huntsville, Ontario V1a

2 Hardwood initiative The context An initiative by FPInnovations, in cooperation with the Canadian Wood Fibre Centre (CWFC) An intensive research and development program aimed at improving the hardwood sector in Eastern Canada A research initiative based on a new business model for the hardwood sector Forest management strategies guided by new industry needs and forest sustainability principles

3 Hardwood Initiative Objectives Propose forest management strategies for the hardwood forests that meet industrial needs without compromising forest sustainability and ecosystem integrity principles Transform the hardwood lumber industry into a client-based industrial structure Optimize the wood product value chain Source:

4 Hardwood Initiative Supported by: Federal New Brunswick Nova Scotia Quebec Ontario

5 Background Our hardwood supply Public forests (mixed) Private forests Canadian American (NA) Source: Encyclopédie canadienne

6 Background Industries served (primary sector) Peeling: High quality logs Large diameter Base of tree High value Lumber: Quality logs Bolts Medium diameter Base of tree and 2 nd section Pulp/Biomass : Low quality logs Small diameter Top log Low value

7 Background Multi-users context (2 nd & 3 rd sector) Furniture Kitchen cabinets Floors Coffins Moldings Products graded according to NHLA rules (National Hardwood Lumber Association) Pallets

8 Background Multi-users context Users Pulp Biomass Lumber $ Peeling Value Chain

9 Hardwood value chain Second life Bioenergy Pulp Lumber Furniture Kitchen cabinets Architectural products (moldings, panelling, staircases, turnery, etc.) Coffins Floors Pallets CUSTOMERS Peeling Doors& windows Second life

10 Recent changes to the value chain Pulp & paper 1. Reduced demand for certain types of papers -Newsprint - New production units (South America, Asia) - Strength of the Canadian dollar compared to the US dollar 2. Pulp log volume surplus - Decline of hardwood forest quality - Reduction of mill production

11 Recent changes to the value chain Primary processing - Lumber manufacturing 1. Decline of raw material quality - Decrease of superior quality volume - Closure of softwood sawmills - Processing of low quality logs (bolts) 2. Competitivity loss - Raw material cost - Lumber supply superior to demand - Strength of the Canadian dollar compared to the US dollar

12 Recent changes to the value chain 2 nd and 3rd Manufacturing 1. Shift of North American 2 nd and 3rd manufacturing units toward Asian countries - Plant closure and dismantling - Lumber supply superior to demand 2. Competitivity loss on mass products - Manufacturing cost - Labour availability - Strength of the Canadian dollar compared to the US dollar

13 Recent changes to the value chain Second life Bioenergy Pulp Furniture Value chain modified and Kitchen cabinets Lumber imbalanced Architectural products (moldings, panelling, staircases, turnery, etc.) Coffins Floors Pallets CUSTOMERS Peeling Doors& windows Second life

14 New elements of the value chain Processing New elements of the value chain Processing New elements - New technologies under development - Changing world market - Users are seeking supply adapted to their needs - Dimensions - Moisture content - Quality (defects accepted)

15 Opportunity Products adapted to users Furniture Kitchen cabinets Floors Coffins Moldings Products graded according to user needs Pallets

16 Technology development 35% Reduced moisture content variability Board by board control 30% 25% 20% 15% 10% 5% 0% Teneur en humidité (%) 100% 80% 60% 40% 20% 0% Teneur en humidité (%) Source: PMP Solutions

17 Technology development Séchage du bois Radio Frequency continuous drying kiln Moisture Content 50% 45% 40% 35% 30% 25% 20% 15% hours hrs! instead Instead of of days hrs! Sugar Maple 4/4 10% 5% 0% 0,0 0,5 1,0 1,5 2,0 2,5 3,0 Time (hours)

18 Technology development Lumber grading according to in-house grades Dimensions Moisture content Defects and attributes Colour Knots Ect. Multisensor systems

19 Opportunity Harvesting Opportunity Harvesting New elements - Harvesting driven by silvicultural prescription and industry needs - Mechanization of logging operations : - Timber harvesting - Biomass harvesting - Integration of new technologies - Increased need for segregation in the forest

20 New elements of the value chain Forest New elements of the value chain Forest New elements - Better knowledge of the resource is required (volumequality-value) - Developement of new low quality hardwood users (bioenergy, bioproducts) - Evaluation and deployment of silvicultural strategies adapted to the actual forest, to regeneration, to the industrial structure and to the optimization of the value chain (practical projects).

21 Forest knowledge Forest knowledge LiDAR Scan Volume Quality Value Prediction of wood value and properties

22 Silvicultural opportunities: improve quality Silvicultural opportunities: improve quality Precommercial and commercial thinnings

23 Hardwood Initiative Roadmap : Processing Markets Users needs Manufacturing Process Sawmill supply needs Ecodesign Life cycle Needs of 2nd & 3rd manufacturing users Linking to quality requirements Adapted lumber; avoiding checks; discoloration Transformation drying Logs quality National issue

24 Hardwood Initiative Roadmap : Silviculture Markets Users needs Manufacturing Process Sawmill supply needs Ecodesign Life cycle Needs of 2nd & 3rd manufacturing users Linking To quality requirements Adapted lumber; avoiding checks; discoloration Transformation drying Logs quality Forest inventory to assess economic value Impact of partial harvesting (Acadian Forest Region) Economic & Silvicultural knowledge Optimizing deployments Merchandizing centers Improving control Extensive/intensive treatments Improving performance Regional issue

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26 Focus on specific projects

27 Program Area Sector of Activity Projects Market analysis User need analysis Manufacturing Processes Analysis Definition of sawmill supply needs Improving harvesting control Improving harvesting performance Process Technology Silvicultural treatments Protecting residual forests Knowledge of 16 economic and silvicultural opportunities 17 1 Product Life Cycle Analysis 2 Critical design parameters to the ecoconception of engineered wood products 3 Identification of 2 nd and 3 rd transformation users needs * 4 Linking user needs and required lumber quality 5 Economic impact of bioenergy and bioproducts on hardwood harvesting and processing 6 Assessment of a breakdown process tailored to the lumber requirements of 2nd and 3rd transformation users 7 Defining best practices against checks and splits throughout the value chain 8 Biological staining of wood 9 Definition of the manufacturing technologies required 10 Utilization of RF for drying hardwoods 11 Log characterization in relation to user needs 12 Optimization of operational deployments (Increased treatment polyvalence) 13 Merchandizing centers 3 projects completed (3, 6 and 10) Improvement treatments for extensive management (without marking) P. Meek: Increasing the protection of stands under intensive management (with marking) Designing forest survey to assess the properties and economic value of Eastern Canada hardwoods Impact of partial harvesting on tree grade projections for northern hardwoods of Acadian Forest Region 18 Impact of precommercial thinning in hardwood stands

28 1 Product Life Cycle Analysis (LCA) J. O Conner / P. Lavoie Objective(s): Develop cradle-to-gate life cycle assessment of hardwood products produced by lumber, furniture, flooring, kitchen cabinets, architectural products and pallet industry sectors. Produce data on environmental impact of hardwood products.

29 What is LCA? Extraction matière première/ Raw material extraction Transformation / Processing Recyclage / Recycling Réutilisation/ Reuse Élimination / Disposal Impact total du produit sur l environnement Démolition Construction sur chantier/ Construction at the site Occupation / Occupancy Entretien / Maintenance Analyse du cycle de vie Évaluation intégrale d un produit quant à son impact sur l environnement Life Cycle Assessment Exhaustive analysis of a product to assess its environmental footprint

30 1 - Results of LCA for wood 300% Impact environnemental de divers types de mur extérieurs / Environmental impact of different types of exterior walls 250% Impact par rapport au bois 200% 150% 100% Bois / WOOD Blocs de béton Béton / CONCRETE Formes de béton isolée Acier /STEEL Panneaux structuraux isolés 50% 0% Énergie/ Energy Changements Climatiques/ Climatic changes Pollution de l air/ Air pollution Source: Athena EcoCalculator

31 3 - Identification of the needs for 2 nd and 3rd transformation users (N. Pearson) Completed 27 companies participated in the data collection Information covers 3 aspects: lumber supply, dimensions and quality of components Wood Supply Usually very high quality lumber is used, except for flooring, pallet and furniture manufacturers

32 4 - Linking user needs and required lumber quality J. McDonald / N. Pearson Objective(s): Translate the specific needs of secondary and tertiary transformation users into sawing guidelines for manufacturing components* according to their specifications. * in terms of dimensions, quality and grading face required

33 6 Evaluation of breakdown processes based on secondary and tertiary manufacturing requirements (J. McDonald) Completed Objective(s): Determine the most efficient breakdown process and method for the production of lumber meeting the needs of secondary and tertiary manufacturers. Quantify the volume and value gains derived from the production of lumber meeting the needs of secondary and tertiary manufacturers.

34 6 - Evaluation of breakdown processes based on secondary and tertiary manufacturing requirements (J. McDonald) Components recovery by sector BorealScan board scanner

35 6 Results of sorting lumber according to optimum component recovery with BorealScan (J. McDonald) COMPARAISON - SITUATION ACTUELLE SANS TRIAGE VERSUS MEILLEUR RENDEMENT INCLUANT RENDEMENT MINIMAL COMPARISON - ACTUAL SITUATION WITHOUT SORTING VERSUS BEST RECOVERY INCLUDING MINIMAL RECOVERY Plancher Flooring Escalier Stair Armoire Cabinet Moulure Molding Meuble Furniture Panneaux Panelling Palette pallet Components recovery - increase SITUATION ACTUELLE SANS TRIAGE / ACTUAL SITUATION WITHOUT SORTING Rendement moyen Average recovery 53.4% 61.5% 66.2% 43.5% 61.8% between 6.4% 64.7% and 75.4% 48.0% $ / Mpmp - sciage $ / Mbf - lumber 644$ 933$ 1 090$ 1 375$ 756$ 1 025$ furniture (-7.6%) 260$ $ / Mpmp - composants $ / Mbf - components 1 206$ 1 517$ 1 645$ 3 164$ 1 224$ 1 585$ 541$ MEILLEUR RENDEMENT INCLUANT RENDEMENT MINIMAL / BEST RECOVERY INCLUDING MINIMAL RECOVERY Rendement moyen 61.9% 71.5% 70.5% 76.2% 57.1% 72.9% 54.2% Average recovery Supply costs in $/Mbf $ / Mpmp - sciage 610$ 960$ 909$ 1 095$ 648$ 939$ 260$ $ / Mbf - lumber components $ / Mpmp - composants $ / Mbf - components 985$ 1 343$ 1 289$ 1 436$ 1 135$ 1 288$ 479$ DIFFÉRENCE P/R À LA SITUATION ACTUELLE / DIFFERENCE BASED ON ACTUAL SITUATION Gain ou (perte) de rendement Recovery gain or (loss) 15.9% 16.4% 6.4% 75.4% (7.6%) 12.8% 12.9% Réduction ou (hausse) du coût d approvisionnement / Supply cost reduction or (increase) $ / Mpmp - sciage $ / Mbf - lumber 34$ (28$) 181$ 280$ 108$ 86$ 0$ $ / Mpmp - composants $ / Mbf - components 221$ 174$ 356$ 1 728$ 89$ 297$ 62$ depending on the sector except Supply costs in $/Mbf lumber Reduction range from $0 to $280 except for stairs (increase by $28) Reduction range from $62 to $1,728

36 8 - Colouring and Decolourizing Wood via Biotechnology (D.-Q. Yang/M.Gignac) Objective(s): Develop a biological technology to eliminate undesirable wood colours and to produce attractive and consistent wood colours and patterns Increase the value of low grade lumber

37 8 - Colouring and Decolourizing Wood via Biotechnology (D.-Q. Yang / M.Gignac) Identify suitable fungi for coloration

38 8 - Penetration of coloured wood with fungi

39 10 - Utilization of RF for drying hardwoods (V. Lavoie) Objective(s): Identify with industry potential applications for progressive highfrequency drying and evaluate the technical and economic feasibility of such applications. *RF: radio frequency

40 10 - Utilization of RF for drying hardwoods (V. Lavoie) Generator Convoyor kiln Moisture content (%) Teneur en humidité 50% 45% 40% 35% 30% 25% 20% 15% 2.4 hours! instead of 15 days Sugar Maple test 4/4 thickness 10% 5% 0% 0,0 0,5 1,0 1,5 2,0 2,5 3,0 Temps de séchage (heures) Drying time (hr)

41 16, 17 and 18: Improved forest inventory (Terrestrial LiDAR) & Impact of thinnings on hardwood quality (I. Duchesne/C.-H. Ung/E. Swift) LiDAR Scan Prediction of wood value and properties Volume Quality Value BorealScan External stem form model for Optitek CT-Scan

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