Procurement Supply Chain for the Biorefinery Vl Value Chain

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1 Intégration des procédés dans l industrie papetière Process Integration In the Pulp & Paper Industry Project t2 3.10: 310 Optimizing i i the Biomass Procurement Supply Chain for the Biorefinery Vl Value Chain Jose Melendez, École Polytechnique de Montreal Project Director: Paul Stuart, École Polytechnique Project Co Director: Luc LeBel, Laval University Apr. 9 th, 2013 VCO Biomass Workshop Pointe Claire, Quebec

2 Outline Project Background and Context: Biomass Supply Chains and the Biorefinery Transformation Commodity vs. Value Added production Project Objectives Description of Forestry Case Study Forest Feedstock Supply Chain Characterization Results (Forestry) Quantities, Costs, Alternative scenario comparisons Optimization Biorefinery Transformation Scenarios 2

3 Context: Biorefinery Biomass Supply Chain Forestry Wood Products Pulp & Paper Forestry, Wood Products and Pulp & Paper all have a symbiotic relationship: existing supply chains, harvesting know how and cost sharing, access to biomass, etc. 3

4 Context: Cost of Biomass and Biorefineries Delivered feedstock costs represents the single largest component of total product cost for commodity product biorefineries (40% 60%). In addition: Be prepared for increasing competition for biomass (pulpwood, sawmill residues, roadside residues, etc.) over the long term Sudden changes in sawmill and pulp mill production and changing demand from emerging gplayers (i.e. pellets, bio energy) may raise the price of biomass feedstocks for all interested participants Guarantee of biomass on a long term basis is essential for financing & economic viability of a biorefinery [Renner, 2010] 4

5 BRF Design: Commodity vs. Value added Commodity production: E.g. CHP, Pyrolysis oils, biofuels via gasification, pellets, etc. Feedstock represents 40% 60% of total selling price Large volume production with a low profit margin Reducing feedstock costs increases our profits Therefore the goal of the optimization model is to maximize biomass quantities for a target (minimum) cost $120 $100 $80 $60 Threshold cost Minimum cost e] Product Selling Price, [$/tonne Profit Margin Operating i Cost Feedstock Cost Average $/tonne, distance from mill Commodity 5

6 BRF Design: Commodity vs. Value added Value Added production: E.g. CNC, Carbon Fibre from lignin, biochemicals, etc. Procurement of higher quality feedstock in the necessary quantity is essential for success of your biorefinery Feedstock represents lower percentage of total selling price (~20 40%) Lower quantity production with a larger profit margin, but only to supply enough biomass to meet en product market demand. Therefore the goal of the optimization model should be to satisfy the targeted quantity and quality of biomass while minimizing procurement costs, [$/tonne] Product Price, P e Market Demand Supply 40% 60% 20% 40% Profit Margin Operating Cost Feedstock Cost P e Commodity Value Added Quantity, [tonnes] Q e 6Product ct Selling Price, Price[$/tonne] e,

7 Project Objectives To examine biomass procurement strategies which satisfy existing P&P mill and future biorefinery feedstock quantity and quality requirements, for economic viability. To carry out the modelingof of a biomassprocurement supply chain for the existing mill, and then the impact of business and technology changes which may occur during a biorefinery transformation process. To model biomass procurement rement for two odifferent production regimens in a biorefinery: production of commodity and value added products. 7

8 Case Studies Agriculture based biorefinery case study utilizing both triticale grain and straw for production of different bio product portfolios (ethanol, PLA, bio materials) Newsprint mill case study currently has high h wood procurement costs, and at the same time would like to consider biorefinery opportunities (commodity or value added) added) With these concerns in mind, this study examines harvesting strategies, and the potentialimpactthatimpact that these mayhave on (a) feedstock costs for core business, as well as (b) creating potential for additional low cost biomass through operating synergies 8

9 Case Studies Agriculture based biorefinery case study utilizing both triticale grain and straw for production of different bio product portfolios (ethanol, PLA, bio materials) Newsprint mill case study currently has high h wood procurement costs, and at the same time would like to consider biorefinery opportunities (commodity or value added) added) With these concerns in mind, this study examines harvesting strategies, and the potentialimpactthatimpact that these mayhave on (a) feedstock costs for core business, as well as (b) creating potential for additional low cost biomass through operating synergies 9

10 Case Study Mill: Forest Stand Description Forest Stands: Harvested Forests are composed mainly of small diameter softwood (spruce, fir) with some hardwoods (poplar, birch, aspen) mixed in. Current harvest method used: Cut to Length (CTL) Softwood pulp and sawlogs are removed from the forest Some removal of unmerchantable logs (used as fuel wood) Tops and branches left in the forest (poor soils) 10

11 Cut-to-Length Harvesting Supply Chain Cut to Length Method and Pulp Mill s Biomass Supply Chain Forest Stands Roadside Sawlogs Sawmill Chips Harvester Bark/sawdust Log Loader Forwarder Pulp logs Pulp mill Fuel wood Co Generation Log Truck 11

12 Case Study Mill: Biomass Supply Chain Cut to Length Whole tree harvesting Method with and Pulp Residue Mill scollection Biomass Supply Chain Sawlogs Forest Stands Harvester Feller Buncher Chips Log Truck Forwarder Skidder Sawmill Bark/sawdust Pulp logs Log yard/ Pulpmill Fuel wood Co Generation Co Generation Roadside Grinding Log Loader De limb/bucking Residues 12

13 Potential Yield from the Forest Simulation models were built in order to determine types, quantities, and costs of harvesting different types of materials from forest stands and farm land Total Products and by products produced per hectare, [bdmt/ha] Sawlogs Spruce 40 Hardwood Fir 0 Sawlogs Pulp logs Fuel woodlogs Merchantable Logs with bark Branches Foliage 13

14 Procurement Costs by material Cos sts, [$/bdmt] 110 Transportation 100 Preprocessing & Storage 90 Overhead Profit Allowance Others Costs Loading Forwarding Harvesting 0 Sawlog costs Pulp log costs Fuelwood cost 14

15 Cost of Biomass Feedstocks Cost, [$/bdmt t] Whole tree Harvesting Scenario CTL with residue harvesting scenario Current CTL harvesting scenario Not So Good for the Biorefinery Really Good for the Biorefinery! Total Sawlog chips Pulp log chips Fuel wood biomass Residue biomass 15

16 Outline Project Background and Context: Biomass Supply Chains and the Biorefinery Transformation Commodity vs. Value Added production Project Objectives Description of Forestry Case Study Forest Feedstock Supply Chain Characterization Results (Forestry) Quantities, Costs, Alternative scenario comparisons Optimization Biorefinery Transformation Scenarios 16

17 Case Study Mill: Biomass Supply Chain Material Source Preprocessing Locations Customers Sawmill Forest Stands Log yard & fiber room Log yard/ Pulp Mill Roadside Preprocessing Co Generation Satellite facility 17

18 Value Added Bioproduct Assessment: Optimization Model Formulation (on going work) Harvesting Transportation Pre processing Forest inventory limits Harvesting process selection Costs per process selection Product Demand Material flows to sawmills, pulp mills, storage, etc Material/Product conversion rates Exchange Limitations 18

19 Ongoing Work: Optimization p Model Case Studyy Multiple Forest Stands with 3 separate wood species in varying quantities and 4 different quantities, products Three harvesting methods run by four different contractors each with their own costs Four different sawmills willing to exchange chips for sawlogs, but distance variations may or may not prove beneficial. Biorefinery Transformation: High/Low Quantity/Quality q for future requirements biorefineries

20 Biorefinery Transformation How do we satisfy future biorefinery feedstock quantity and quality requirements? How will business and technology changes in the supply chain affect the bottom line? 20

21 Biorefinery Transformation: Biomass Supply pp y Chain Material Source Agriculture Feedstocks, Residues Forest Stands Plantation logs Construction Debris, MSW Preprocessing Locations Customers Sawmill Thermochemical Roadside P li i Pyrolisis Bio chemical Log yard & fiber room Pulp Mill Roadside Preprocessing Satellite densification or fractionation Satellite facility Co Generation Co Generation Composites 21

22 Summary The goal of this presentation was to introduce work being carried out in designing biomass procurement strategies that fit in with the changing forest industry. Completed: Study of biomass procurement operations has proven that by combining new technologies with innovative harvesting methods, it is possible to reduce biomass procurement costs Ongoing: Show that for biorefineries, biomass procurement costs should be analyzed and decisions must be taken to optimize biomass supply chain according to the biorefinery volume requirements and product portfolio. 22

23 Acknowledgements Funding Natural Sciences Engineering and Research Council of Canada (NSERC) Environmental Design Engineering Chair Value Chain Optimization Network (VCO) Forest Product Innovations (FPI) Many thanks to the personnel at the case study mill! 23

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