Innovation in Small Diameter Utilization

Innovation in Small Diameter Utilization Bioenergy & Wood Products Conference II Denver, Colorado March 15, 2006 John R. Shelly University of California Cooperative Extension john.shelly@nature.berkeley.edu

Innovation? Small Diameter?

Dense Stand of Small Diameter Trees

September 2001

October 2001

February 2002

June 2002

February 2003

August 2005

What can we Do with Small Diameter Trees?

What can we Do with Small Diameter Trees? Grind it

What can we Do with Small Diameter Trees? Grind it Chip it

What can we Do with Small Grind it Diameter Trees? Chip it Burn it

What can we Do with Small Diameter Trees? Grind it Chip it Burn it Peel it

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Saw it

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Peel it Saw it

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Saw it Composite Panels Peel Poles

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Saw it Make OSB Peel Poles Make Plastic Composites

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Saw it Make OSB Make Plastic Composites Peel Poles Engineered Lumber

What Can We Do with the Small Diameter Resource? Grind it Chip it Burn it Peel it Saw it OSB Plastic Composites Engineered lumber Peel Poles Make Organic Chemicals Wood = C + O + H

So What s the Problem?

So What s the Problem? Resource Availability Processing Cost Product Quality differential shrinkage knots juvenile wood

Dimensional change in the tangential direction is twice as great as it is in the radial direction

Juvenile Wood Core first 5 to 20 growth rings

4.5 inch, 22 years 5.5 inch, 65 years

8 inch, 39 years 8 inch, 73 years

Juvenile Wood often leads to Warp

The Anatomy of a Crook

Breaking wood down into particles minimizes the impact of inherent property defects (knots, juvenile wood, etc.)

Innovation

Innovation 1. Improve conventional processes to overcome the inherent property limitations

Innovation 1. Improve conventional processes to overcome the inherent property limitations 2. Develop new processes

Innovation 1. Improve conventional processes to overcome the inherent property limitations 2. Develop new processes 3. Develop new products

Lumber Processing Innovation

Lumber processing Innovation Roundwood Construction

Innovation Roundwood Construction Slide provided by USDA Forest Service, Forest Products Lab

Connections are Difficult Slide provided by USDA Forest Service, Forest Products Lab

It Can Be Done! Verification of design values is necessary to obtain building code approval Photo courtesy of USDA Forest Products Lab

Innovation Lumber Processing Roundwood Construction Wood-Plastic Composites

Demand for Natural and Wood Fiber-Plastic Composites Thousand Tons 800 600 400 200 0 1994 1996 1998 2000 2002 2004 Year Adapted from Morton, Quarmley, and Rossi. 2004. Seventh International Conference on Wood Fiber Plastic Composites. Forest Products Society, Madison, WI

Lumber Processing Roundwood Construction Wood Plastic Composites Energy Conversion Innovation

California Biomass Energy Facilities Sawmill Cogen Other Biomass Power Plants 30 + MW 20-30 MW 10-20 MW 0-10 MW Total Capacity ~ 625 MW Biomass Consumption 4.5 million BDT per year of which 22% is forestbased A 10 MW (megawatt) generator can supply electricity to about 10,000 homes.

Densified Solid Wood Fuels Firelogs Fuel Pellets

Densified Fuel

Lumber Processing Roundwood Construction Wood Plastic Composites Energy Conversion Chemical Production Innovation

Lumber Processing Roundwood Construction Wood Plastic Composites Energy Conversion Innovation Chemical Production Softwoods Hardwoods Cellulose 40-44 % 43-47 % Hemicellulose 25-29 25-35 Lignin 25-31 16-24 Extractives 1-5 2-8 Ash < 1 < 1

Organic Chemicals from Biomass Many Valuable Chemicals can be Made from Wood Pharmaceuticals and Fragrances -- Extraction Charcoal, phenolic oils, methanol -- Pyrolysis Bio-Gases (low BTU, high CO) -- Gasification Levulinic and Lactic acid ( building blocks ) Hydrolysis/Conversion Ethanol -- Hydrolysis/Fermentation or Thermal Reduction/Catalytic Conversion

Gasification Process (In excess of 600 o C) Biomass Pyrolysis Producer gas Char & Ash Char Conversion Char & Ash Heat Heat Combustion Ash & Exhaust Gases SO 2 ~ 0.15 lbs per million BTU NO x ~ 0.05 lbs per million BTU CO ~ 0.05 lbs per million BTU Particulates ~ 0.025 lbs per mill ion BTU

Thermal Reduction/Catalytic Conversion Biomass Gasification C, OH tar Producer gas (syngas) heat Catalytic Conversion Bio-diesel Ethanol Methanol

Biomass to ETOH Technologies Hydrolysis/Fermentation Concentrated Sulfuric Acid Dilute Sulfuric Acid Dilute Nitric Acid Enzymatic Thermal Reduction/Chemical Conversion Gasification/Catalytic Conversion (Fischer- Tropsch)

Hydrolysis/Fermentation Dilute nitric acid hydrolysis Separates the 5 and 6 carbon sugars from the lignin

Hydrolysis/Fermentation Dilute nitric acid hydrolysis Separates the 5 and 6 carbon sugars from the lignin Yeast Fermentation Converts sugars to alcohol

Challenges for Manufacturing Biomass-Based Products Insure a Long-Term Supply of Biomass Raw Material Overcome Material Property Limitations (biomass is a low quality raw material) Reduce the High Handling and Production Costs Improve Processing Knowledge Develop New Markets or Market Share Encourage Research Funding and Investment Capital

Future Small Tree Innovation Improve conventional technology Overcome inherent property limitations More economical Greater energy efficiency

Lower the cost of removing the resource from the forest and getting it to the processing plant

Future Small Tree Innovation 1. Improve conventional processes 2. Develop new processes 3. Develop new products

Future Small Tree Innovation Could it be Nanotechnology? one billionth of a meter New generations of lignocellulosic materials Directed breakdown of carbohydrates and/or lignin Self assembling polymers Harness the potential of trees as photochemical factories