sustainability University of Turin, Italy Neeta Sharma - ENEA, Italy

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1 Logistics and sustainability Remigio Berruto, Patrizia Busato University of Turin, Italy Neeta Sharma - ENEA, Italy

2 Biomass chain success factors and Advantages CO 2 neutral No taxes low production cost Local economy delopment Positive cash flow Waste residues value (e.g. corn with mycotoxins, straw) High yield less area Incentives? Other use? problems Problems Nonuniform (e.g. moisture, composition, quality) Availability yield Storability Market (risk) Logistics issues (e.g. storage, JIT) Equipment investment (risk) Training on production (risk) Sustainable for the soil? The more items you able to drop on the right of this list, the more successful will be the biomass chain hi If it is not feasible by logistic point of view, it will not be done

3 Sustainability of production Crop store (solar) energy crop, to grow use other resources: land, water, energy (from sun, fossil fuels) Crop needs to be transported, stored energy, losses KPI example: Output/input ratio: efficient conversion of the input energy into output energy Net energy produced/ha: efficient use of soil/water resource The destination of energy/material produced and USED from biomass/fibre changes both the above indexes

4 Impact of yield and distance Logistics (harvest & transport): Corn silo (18 tdm/ha, GJ/ha) 13 5 km BCR, km BCR [biomass collection radius] Corn silo (18 tdm/ha, GJ/ha), km BCR, km BCR Corn stover Canada (4.55 tdm/ha, 63 MJ/ha): ) 22 /tdm (within 5 km BCR) Rice straw (3 tdm/ha, 48 GJ/ha): ) 33 5 km BCR, km BCR (low yield more expensive than corn silo) Low yield or high h distances imply higherh logistic i costs

5 Rice straw Green fields 33 /t DM all fields (included red ones) 77 /t DM

6 Logistic costs ($.ton 1 ) corn silo Field distance Number of wagons available (km)

7 Energy use Transport impact: energy use and PS type container vessel (11,000 TEU) S type container vessel (6,600 TEU) emissions i Rail Electric Rail Diesel Heavy Truck Boeing kwh/t km Emissions PS type S type Rail Rail Diesel Heavy Truck Boeing 747 g/tkm Electric 400 container vessel (11,000 TEU) container vessel (6,600 TEU) CO SOx NOx PM n/a n/a Source: Network for Transport and the Environment 7

8 Impact of harvest procedures: reduce the number of passes Corn stover cut& windrowing one pass cornrower head for combines One pass instead of three (grain harvesting, stalks cutting, stalks windrowing) Cost reduction of 12 /t DM 60 /ha Reduction of 18% of energy used compared vs. traditional 3 passes

9 Increase density in transport Corn stover, Canada From round bales to square bales Large square baler high capacity better transport utilization Bale weight: 172 kg DM/round bale, 202 kg DM/large square bale same number of bales in transport, high h use of truck capacity High capacity in the operation with high density 20 /ha savings (could bemore on long distances)

10 Energy consumption for slurry distribution ib ti 3500,0 3000,0 2500,0 MJ/ /ha 2000,0 1500,0 1000, (1 passage) 340 (2 passages) 200 (2 passages) 300 (3 passages) 500,0 0, Field distance from Biogas Plant (km) In large biogas plant, distribution could play an important role in terms of costs and energy consumption

11 Improve sustainability in production irrigationi and fertilizers Irrigation: Sprinkler irrigation: i add 8GJ/h GJ/ha It is possible to save 450 m 3 /ha 152 Mm 3 /year in Piemonte Region, with associated energy ( GJ/year at low consumption rate) Reduce inputs: e.g. mineral fertilizers (14.3 GJ/ha) Reduce losses: e.g. just in time delivery, no storage

12 Energy balance use of mineral fertilizers Parameters Rape seed Wheat Sunflower Corn Grain Input Output Input Output Input Output Input Output (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) Fuel Fertilizers Energy Input (totals) Energy Outputs (total) Net energy Net energy (toe/ha) 2,52 4,31 2,60 4,10 Ratio Output / Input 6,53 8,31 7,58 5,63

13 Energy balance of crops use of digestate t Parameters Wheat Sorghum silo Corn grain Corn Silo Input Output t Input Output t Input Output t Input Output t (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) (MJ/ha) Fuel Energy Input (totals) Energy Outputs (total) Net energy Net energy (toe/ha) 2,98 5,18 3,30 4,79 Ratio Output / Input 11,18 18,44 7,21 14,25

14 Reduce drying costs (when needed) Drying: impact For corn is equal to fuel used for operations (add 8 GJ/ha) Expenses are greater for lignocellulosicll l i feedstocks!! (a lot of material, at 40-50% MC) Drying with fossil fuel costs 0,09 /kwh t 40.5 /t NOT FEASIBLE Should be avoided d to make higherh net energy retrieval ti Or should be done with heat waste

15 Example of use of heat waste Sustainable drying 1 MWe biogas plant 8400 MWh e/year MWh t MWh t /year t/year fresh material (50% MC) 8400 t dry material at 20% MC Drying need from 50% to 20% MC 450 kwh energy cost (0,02 /kwh) 9 /t 50% (fresh) FEASIBLE

16 Improve energy use/land use Corn grain For drying: kg/t of corn grain 3-5% of area (3-5 ha every 100 ha) very SHORT supply chain Corn grain For heating: 1MW thermal 140 kl diesel 300 t of corn ha (all energy used, 80-85% 85% yield) 190 GJ/ha/year Electric energy (with biogas), 1MWe: ha (a lot of thermal energy wasted ~ 60%) GJe/year 79.3 GJ/ha/year (high energy quality and usability) Biomethane Injection (with biogas): GJ/year Good fuel also for transport (167 GJ/ha/year) Biofuels/biomaterial made with efficient process, use of all the material Use of marginal land (keep in mind it is marginal)

17 Improve water quality and quantity Biomass, if located and managed right, could increase water quality: pesticide reduction 30%, nutrient reduction 50%; sediment loading reduction 50% (work with Purdue University, USA)

18 Challenges in biomass/fibre production Improve logistics and reduce distances (both economic and environment affected) not too big plants, unless cheap transport avaialable (e.g. rail, barge) Technologies and crops to improve yield (ASABE 2010: top farmers +25% yield) reduced land use Increase water efficiency, water quality, fertilizer efficiency Economic use of residues reduced land use Just in time delivery reduced operation time, no drying Drying with wasted heat from processing/energy plants Reduce field losses (50% for corn stover, dried in the field) with less passes for harvest Increase ratio of material/energy produced vs. resource used (energy used, water used, land used) use all the material

19 Challenges in biomass/fibre utilization Better, complete use of feedstock, yield while making biofuels/biochemicals Provide frameworks and tools that allows the assessment for free, case by case, of the BAT (best available techniques), logistics and sustainability Regulations - the major driver in Europe Emissions environmental, political issue Incentives (subsidy are paid by ALL)

20 Bioenergy Farm Project Sustainability assessment of biomass production Free tools over the web no installation Economic and energy balance of biomass crops (and residues e.g. straw) 7 languages so far (EN, IT, NL, DE, PL, BE, EE) and country specific data Include also forestry biomass assessment

21 Conclusions When estimate the biomass/fibre exploitation potential, we should consider also: Logistics (distance, density, storage, intermodal, harvest procedures) Sustainability (also the economic one) Great improvements are possible: Increase the yield Increase the use of energy/chemical content Reduce waste and losses (transport, use of heat waste for drying, storage, process) We are part of the FP7 SAHYOG (coordinator Dr. Neeta Sharma, ENEA) Coordination activities between Europe and India SRA and future road map on biomass and bio-waste zero waste birefineries i

22 Be sustainable also means to buy the time, to extend the time we (our childrens) could afford our lifestyle, Hunter Lovins, author of natural capitalism i i