Machinery and systems in different scales of forest fuel supply chains

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1 BIOMASS PRODUCTION: ENERGY FROM FORESTRY AND AGRICULTURE 21st-22nd November 2005 Elgin, Scotland Machinery and systems in different scales of forest fuel supply chains Lauri Sikanen, Dominik Röser & Antti Asikainen METLA 1

2 DEVELOPING SMALL AND MEDIUM SCALE WOODFUEL SUPPLY CHAINS 2

3 Aim of the presentation To describe approaches in different scales of forest fuel procurement used in Scandinavia AND Try to tailor them for the Scottish operational environment 3

4 Definition of forest fuel Wood-based fuels Energy Forest Forest Biomass Recycled wood Short Rotation Forestry Primary residues Forest Residues Logging residues Residues from first and intermediate thinnings Stumps Roundwood for energy Traditional firewood Secondary residues Industrial Residues Bark Sawdust Shavings and chips Endings and cross-cut ends Black liquor Used wood from Construction Demolition Wooden Packages 4

5 Small scale users: Farms, offices, visitor centres, private houses etc. FUELS kw 5

6 Medium scale users: Municipality size MW FUELS 6

7 Large scale users: : City size for example: Alholmens Kraft The biggest biofuel energy plant in the world MW combined heat and power Charcoal 10% FUELS Wood 45% Total use of wood fuels GWh/a Forest residues m 3 = 300 GWh/a Peat 45% 7

8 Transportation of woodfuel fractions Proportion of solids in uncompacted logging residues and tree-sections, wood chips and conventional pulpwood. All loads have the same solid content. (After Nilsson 1983). 8

9 The main sources of forest fuels Small diameter trees from early thinnings - Harvesting costs are high - Cost difference to logging residue chips is about /m³ - Resources difficult to locate, measure and get to market - Integration with roundwood harvesting is weak Logging residues and stumps from final fellings - A side product of final cuttings - Accumulation easy to estimate and locate - Integration with roundwood harvesting is great - Harvesting costs are quite low Rounwood from final fellings - Effective operations - Traditions exist -Goodqualitychips 9

10 Production methods of chips from small-sized sized trees Manual felling and piling of small-sized stems Felling frame Pile of small-sized delimbed or undelimbed trees near forest road Forest haulage of small-sized trees Chipping Transportation to heating plant Heating plant Accumulating feller-buncher 10

11 Manual felling-bunching chainsaw with special handles no delimbing: more biomass, less time for cutting manual piling 11

12 Mechanized felling-bunching 12

13 Supply chains for logging residues (or log chips) BUNDLING METHOD Bundling of logging residues Forest haulage by tractor equipped for log haulage On-road transportation by log trucks Logging residue compacting truck trailer On-road transportation of loose logging residues TERRAIN CHIPPING-METHOD Chipping of residues on road-side terminal LOOSE RESIDUES Crushing of bundles or loose residues in the plant CHIPPING IN ROAD SIDE-METHOD 13

14 Logging method for recovery of logging residues 14

15 Location of chipping Chipping is primary element of forest fuel supply chain affecting remarkably to whole set up Principles Pros & Cons 15

16 Chipping in terrain Hakkila Low transport costs same machine doing two tasks (forwarding, chipping) - Small roadside storage - Less interactions between chipping and truck transporting - High chipping costs because of the forwarding - Forwarding distance has to short and flat & well-bearing ground is needed - Payload of a container truck is considerably smaller than that of a chip truck with immovable load space - Not popular method in the future. 16

17 Chipping in terrain Purchase price: EUR Productivity (250 m): 9.5 m 3 /E0-h Unit cost: EUR 12/m 3 Purchase price: EUR Volume (3 cont.): 105 m 3 (loose) Unit cost (40 km): EUR 5.0/m 3 17

18 Chipping at landing Hakkila 2004 High load volume Possibility to use quite efficient chippers In the roadside chipping the chipper and truck are dependent on each other, hot chain Translocation of chipper decreases capasity utilisation Needs space for machines/trucks 18

19 Chipping at landing: : Small & medium scale Farm tractor + chipper 19

20 Chipping at landing: : Medium & large scale Truck-based chippers Hakkila

21 Chipping at landing Purchase price: EUR Productivity: 33 m 3 /E0-h Unit cost: EUR 5/m 3 Purchase price: EUR Volume: 115 m 3 (loose) Unit cost (40 km): EUR 4.4/m 3 21

22 Chipping at plant 22

23 Chipping at plant - Simple to organise - Low chipping costs - Requires short transportation distance with low density fractions (e.g. stumps or unbundled residues) - Requires large scale and steady demand through the year (> 50 MW and > m 3 /a - Requires careful planning of logistics in order to avoid queuing of lorries 23

24 Summary: Chipping - in terrain - at landing - at plant - In the landing (roadside) chipping the chipper and lorry are dependent on each other, hot chain - Chipping at a plant makes the chipper & chip truck independent of each other - Low bulk density/load volume of unprosessed material is the weak link in the chipping at plant system. Not a problem with roundwood - End use facility chipping system is suitable only for large plants since the investment cost is high. - Landing (roadside) chipping system is suitable also for the small plants - Terrain & terminal chipping are the minority chipping systems in Finland 24

25 Brief analysis of technology selection for Highlands FACTS Low bearing capasity of soil Rounwood for fuel Existing harvesting traditions/entrepreneurs Several medium scale using places apart from each other Plenty of small using places apart from each other High moisture content of roundwood Chip burning boilers Gasification EFFECTS ON SUGGESTED TECHNOLOGY Terrain chipping almost out of question Harvesters and forwarders already exist and are effective Large number of professionals already know what is the name of the game Chipping at plant out of question Mobile effective chipper with large enough feeding capacity Farm scale chippers and local part-time operators needed Storing (with covering) over the summer 25

26 Selection of harvesting technology Complex analysis Annual need for forest fuels and other fuels Annual availability of forest fuels - fuel mix (residues, small trees, stumps) - transport distances in the forest/on road network Location of plant (centre of a town or in the sub urban area)? Size of plant yard (storage)? Municipal DH plant/industrial CHP plant? Dominating technology to produce chips to DH plants Need for GIS-based availability and cost analysis 26

27 Cost structure of forest fuels in Finland Cost, /m Management Road transport Chipping at roadside Forwarding to roadside Felling Small trees, 40 km Small trees, 80 km Residues, 40 km Residues, 80 km 27

28 Benchmarking of Wick district heating scheme and Uimaharju power plant MW Distillery & Houses Softwoodchips as fuel Wick 1 MW Laka mech. grate boiler Mixed woodchips as fuel Annual use loose m 3 Heating: m 3 Pipeline: 2 000m Investment cost: Inverness Loch Ness Edinburgh Newcastle Oulu Uimaharju Joensuu London Helsinki 28

29 Preliminary unit costs calculations of fuel chips in Scotland Preassumptions: Lodgepolepine clearcutting Full lorry net payload (22 tonnes) utilisation Cost at plant, / tonne 50,00 45,00 40,00 35,00 30,00 25,00 20,00 15,00 10,00 5,00 Plant Roadside Terminal 0, Distance, km 29

30 Unit Costs of Fuel Chips Delivered to Plant Roadside Chipping, / tonne (preliminary calculations) Cost at plant, / tonne 50,00 45,00 40,00 35,00 30,00 25,00 20,00 15,00 10,00 Rural development 2.3 p/kwh 2.0 p/kwh VAT Overheads Chipping Harvesting Lorry transportation 5,00 0, Distance, km 30

31 Wick Annual use tonnes / boiler With 40 / tonne =>

32 Near future developments Debarking while harvesting Promising results from natural drying of partly debarked birch stems in piles for chopped firewood Hopefully debarking trials can be done during next summer in Highlands 32

33 builds the future of forest sector through research Thank you for your attention 33

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