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Wood Energy Workshop - Belgrade, Serbia 1Tuloskalvosarja
Metsäteho Oy 09/01/2008
ProductionProduction and and UseUse of Wood of Wood Chips: Chips: ImprovingImproving SupplySupply ChainsChains
Kalle KKalle KäärhrhääMetsMetsääteho Oy, Helsinki, Finlandteho Oy, Helsinki, Finland
[email protected]@metsateho.fi
Wood Energy Workshop26th–27th November 2007, Belgrade, Serbia
Wood Energy Workshop - Belgrade, Serbia 2Tuloskalvosarja
Metsäteho Oy 09/01/2008
Contents
• Background:Metsäteho’s studies
• Supply chains in 2006:Logging residue chipsStump wood chipsChips from small-sized thinning wood
• Production machinery in 2007• Conclusions
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Surveys I
1. Supply Chains of Forest Chips in Finland, 2006
March 2007
2. Visions of the Production and Use of Forest Chips in the Future in Finland
March-April 2007
3. Machinery for Forest Chip Production in Finland, 2007
May-August 2007
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Surveys II
The major forest chip suppliers in Finland were involved in surveys; in alphabetical order:
Hyötypaperi Oy, Koskitukki Oy, L&T Biowatti Oy, Metsäliitto, Stora Enso Wood Supply Finland, Turveruukki Oy, UPM Forest, and Vapo Oy.
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Surveys III
Total volume supplied in 2006 by the forest chip suppliers who participated in the surveys was 4.8 TWh.
4.86.1Total
− 1)0.3Chips from large-sized roundwood
0.61.4Chips from small-sized thinning wood
0.90.9Stump wood chips
3.33.5Logging residue chips
TWh
Total volume supplied by suppliers
Total volume used in Finland (Ylitalo 2007)
Type of forest chips
1) Chips from large-sized roundwood were not included in the surveys.
Wood Energy Workshop - Belgrade, Serbia 6Tuloskalvosarja
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Optional chipping locations> Supply chains
• Harvesting site > Terrain chipping• Roadside landing > Roadside chipping• Terminal > Terminal chipping• Energy plant > Chipping at plant
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SupplySupply chainschains in 2006in 2006> > LoggingLogging residueresidue chipschips
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Norway spruce dominatedfinal felling sites
TypicalTypical removalremoval: 70: 70––110 110 MWhMWh/ha/ha
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Cutting methods for recovering of logging residues
One side of strip road Both sides of strip road
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Stacking of residues into large and high-quality piles
Higher productivity in harvestingHigher residue removalsLess impureness for residues
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Terrain chipping 0%
Drawings: Juha Varhi
© Metsäteho Oy
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Strengths & weaknesses of terrain chipping
Chipping and forest haulage with same unitSmall harvesting sitesSmall roadside storage spaceCleanliness of storage areas after harvesting operations
Ineffective chipping Uneven harvesting sitesSize of terrain chipper’s containerLong forwarding distancesUneven and muddy storage areasBreakdownsWinter conditions
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Roadside chipping (Separate chipper & chip truck)
44%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 14Tuloskalvosarja
Metsäteho Oy 09/01/2008
Strengths & weaknesses of roadside chipping (Separate chipper & chip truck)
FlexibilityConsiderable experience in roadside chippingAvailability of harvesting machinery
“Hot” chainUtilization rate of chipperLarge roadside storage space for residuesSmall and muddy storage areas for machinesUntidy roadside storage areas after harvesting operations
Wood Energy Workshop - Belgrade, Serbia 15Tuloskalvosarja
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Roadside chipping (Integrated chipper–chip truck)
16%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 16Tuloskalvosarja
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Strengths & weaknesses of roadside chipping (Integrated chipper–chip truck)
Chipping and long-distance transportation with same unitNo hot chainChips to several small plantsSmall harvesting sites
Small net load sizeLong transportation distancesLong-distance transportation costsLarge roadside storage space for residuesUntidy roadside storage areas after harvesting operations
Wood Energy Workshop - Belgrade, Serbia 17Tuloskalvosarja
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Terminal chipping (Loose residues)
8%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 18Tuloskalvosarja
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Terminal chipping (Bundled)
5%
Drawings: Juha Varhi
© Metsäteho Oy
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Strengths & weaknesses of terminal chipping
No hot chainGood quality management of chipsSecurity of chip deliveriesChips to several small plantsPlants with small storage fields or stocksSmall harvesting sitesEffective chippingWinter conditions
Establishment expenses of new terminalIdentifying appropriate terminal areasExtra handling timesRelatively high total supply chain costs
Wood Energy Workshop - Belgrade, Serbia 20Tuloskalvosarja
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Chipping at plant (Loose residues)
12%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 21Tuloskalvosarja
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Strengths & weaknesses of chipping at plant (Loose residues)
No hot chainLarge-scale productionPowerful comminutionMost cost-efficient supply chain with relatively short transportation distances
Energy content of loose residue loadsLong transportation distancesLong-distance transportation costsLarge roadside storage space and large storage fields at plants are requiredUntidy roadside storage areas after harvesting operations
Wood Energy Workshop - Belgrade, Serbia 22Tuloskalvosarja
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Chipping at plant (Bundled)
14%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 23Tuloskalvosarja
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Strengths & weaknesses of chipping at plant (Bundled)
No hot chainLarge-scale productionEffective forest haulageLow forest haulage costsSmall roadside storage spaceLong transportation distancesPowerful comminutionLow comminution costs
High bundling costsBundling strings when using slow-speed crushers
Wood Energy Workshop - Belgrade, Serbia 24Tuloskalvosarja
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Supply chains of logging residue chips in Finland, 2004–2006
0102030405060708090
100
2004 2005 2006
Prop
ortio
n of
sup
ply
chai
n (%
) Chipping at plant (Loose)Chipping at plant (Bundled)Terminal chipping (Loose)Terminal chipping (Bundled)Roadside chipping (Int. chipper–chip truck)Roadside chipping (Sep. chipper & chip truck)Terrain chipping
Sources: Kärhä 2005–2007
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Supply chains of logging residue chips in Finland, 2004–2006
0102030405060708090
100
2004 2005 2006
Prop
ortio
n of
sup
ply
chai
n (%
) Chipping at plant (Loose)Chipping at plant (Bundled)Terminal chipping (Loose)Terminal chipping (Bundled)Roadside chipping (Int. chipper–chip truck)Roadside chipping (Sep. chipper & chip truck)Terrain chipping
Sources: Kärhä 2005–2007
Wood Energy Workshop - Belgrade, Serbia 26Tuloskalvosarja
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SupplySupply chainschains in 2006in 2006> > StumpStump woodwood chipschips
Wood Energy Workshop - Belgrade, Serbia 27Tuloskalvosarja
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Norway spruce dominatedfinal felling sites
TypicalTypical removalremoval: 150: 150––180 180 MWhMWh/ha/ha
Wood Energy Workshop - Belgrade, Serbia 28Tuloskalvosarja
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Terminal chipping 18%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 29Tuloskalvosarja
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Chipping at plant 80%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 30Tuloskalvosarja
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Supply chains of stump wood chips in Finland, 2004–2006
0102030405060708090
100
2004 2005 2006
Prop
ortio
n of
sup
ply
chai
n (%
) Chipping at plant (Loose)Chipping at plant (Bundled)Terminal chipping (Loose)Terminal chipping (Bundled)Roadside chipping (Int. chipper–chip truck)Roadside chipping (Sep. chipper & chip truck)Terrain chipping
Sources: Kärhä 2005–2007
Wood Energy Workshop - Belgrade, Serbia 31Tuloskalvosarja
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SupplySupply chainschains in 2006in 2006> Chips > Chips fromfrom smallsmall--sizedsized woodwood
Wood Energy Workshop - Belgrade, Serbia 32Tuloskalvosarja
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Manual cutting of small-diameter woodFelling-piling working method
Photos: TTS
Wood Energy Workshop - Belgrade, Serbia 33Tuloskalvosarja
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Chainsaw equipped with a felling frameApuri and Reo felling frames
Photo: TTS
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SmallSmall--diameterdiameter earlyearly thinningthinning standsstands
TypicalTypical removalremoval: 80: 80––120 120 MWhMWh/ha/ha
Wood Energy Workshop - Belgrade, Serbia 35Tuloskalvosarja
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Removal in small-diameter earlythinning stands
Trees with a breast height diameter of 1–2 cm should not be harvested, and trees 3–4 cm can be harvested with consideration! Source: Kärhä et al. 2006
0
5
10
15
20
25
30
1-2 3-4 5-6 7-8 9-10
11-12
13-14
15-16
17-18 >1
8
Class of diameter at breast height (d1.3), cm
Prop
ortio
n of
har
vest
ed s
tem
s, %
0
10
20
30
40
50
60
70
80
90
100
Prop
ortio
n of
cum
ulat
ive
rem
oval
, %
Harvested stems
Total removal
Wood Energy Workshop - Belgrade, Serbia 36Tuloskalvosarja
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Harvesting systems of small-sized woodTwo-machine system
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 37Tuloskalvosarja
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Harvesting systems of small-sized woodTwo-machine system Harwarder system
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 38Tuloskalvosarja
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Roadside chipping (Separate chipper & chip truck)
69%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 39Tuloskalvosarja
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Roadside chipping (Integrated chipper–chip truck)
4%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 40Tuloskalvosarja
Metsäteho Oy 09/01/2008
Terminal chipping 24%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 41Tuloskalvosarja
Metsäteho Oy 09/01/2008
Chipping at plant 3%
Drawings: Juha Varhi
© Metsäteho Oy
Wood Energy Workshop - Belgrade, Serbia 42Tuloskalvosarja
Metsäteho Oy 09/01/2008
Supply chains of chips from small-sizedthinning wood in Finland, 2004–2006
0102030405060708090
100
2004 2005 2006
Pro
porti
on o
f sup
ply
chai
n (%
) Chipping at plant (Loose)Chipping at plant (Bundled)Terminal chipping (Loose)Terminal chipping (Bundled)Roadside chipping (Int. chipper–chip truck)Roadside chipping (Sep. chipper & chip truck)Terrain chipping
Sources: Kärhä 2005–2007
Wood Energy Workshop - Belgrade, Serbia 43Tuloskalvosarja
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Supply chains of chips from small-sizedthinning wood in Finland, 2004–2006
0102030405060708090
100
2004 2005 2006
Pro
porti
on o
f sup
ply
chai
n (%
) Chipping at plant (Loose)Chipping at plant (Bundled)Terminal chipping (Loose)Terminal chipping (Bundled)Roadside chipping (Int. chipper–chip truck)Roadside chipping (Sep. chipper & chip truck)Terrain chipping
Sources: Kärhä 2005–2007
Wood Energy Workshop - Belgrade, Serbia 44Tuloskalvosarja
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ProductionProduction machinerymachinery in 2007in 2007
Wood Energy Workshop - Belgrade, Serbia 45Tuloskalvosarja
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CuttingCutting smallsmall--sizedsized thinningthinning woodwood
180180
Wood Energy Workshop - Belgrade, Serbia 46Tuloskalvosarja
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Harvester heads in cutting small-sized thinning wood
44 %
38 %
10 %
8 %
Felling head
Feeding harvester head with chain saw
Feeding harvester head with guillotine/shears
Feeding harvester head with chain saw +guillotine/shears
Source: Kärhä 2007
Wood Energy Workshop - Belgrade, Serbia 47Tuloskalvosarja
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Productivity of whole-tree cutting
0
2
4
6
8
10
12
14
16
18
0 10 20 30 40 50 60 70 80
Size of whole-tree stem, dm3
Prod
uctiv
ity, s
olid
m3 /e
ffect
ive
(E0)
hou
r
Felling head
Harvester head with feed rollers
The cross-cutting of large (tall) trees causes the difference in productivity!
Source: Kärhä et al. 2006
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EnergyEnergy woodwood harwardersharwarders
5050
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BundlingBundling
1313
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StumpStump and and rootroot woodwood liftinglifting
120120
Wood Energy Workshop - Belgrade, Serbia 51Tuloskalvosarja
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Stump lifting heads with splitting knife
Photos: A Hirvonen Oy, UPM Forest, Korsun Teräs Tmi
A Hirvonen Oy Steelpa Oy Korsun Teräs Tmi
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Stump lifting heads without splitting knife
Photos: UPM Forest
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Stump lifting heads in excavators
46 %
54 %
Stump lifting head with splitting knife
Stump lifting headwithout splitting knife
Source: Kärhä 2007
Wood Energy Workshop - Belgrade, Serbia 54Tuloskalvosarja
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Weight of excavatorsusing different stump lifting heads
0
20
40
60
80
100
Stump lifting headwith splitting knife
Stump lifting headwithout splitting knife
Shar
e of
exc
avat
ors
(%)
20 –
<20 tons
Source: Kärhä 2007
Wood Energy Workshop - Belgrade, Serbia 55Tuloskalvosarja
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ForestForest haulagehaulage of of energyenergy woodwood
350350
Wood Energy Workshop - Belgrade, Serbia 56Tuloskalvosarja
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Forwarding loose residues Enlarged load space I
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Forwarding loose residues Enlarged load space II
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Forwarding residue bundles Enlarged load space
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Forwarding residue bundles Standard forwarder
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Effect of load size on forwarding costs
0
50
100
150
200
250
0 100 200 300 400 500 600 700 800
Forest haulage distance, m
Rel
ativ
e fo
rwar
ding
cos
ts, %
Loose residues / Standard(4.5 solid m3)
Loose residues / Enlarged(8.5 solid m3)
Residue bundles / Standard(5.5 solid m3)
Residue bundles / Enlarged(12.5 solid m3)
Sources: Rieppo 2002, Kärhä et al. 2004
Wood Energy Workshop - Belgrade, Serbia 61Tuloskalvosarja
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Forwarding residues Residue (thorn) grapple
Wood Energy Workshop - Belgrade, Serbia 62Tuloskalvosarja
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Mobile Mobile chipperschippers and and crusherscrushers
190190
Wood Energy Workshop - Belgrade, Serbia 63Tuloskalvosarja
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FixedFixed stationarystationary crusherscrushers
Photo: UPM Forest66
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VehiclesVehicles for for roadroad transportationtransportation of of energyenergy woodwood and and forestforest chipschips
190190
Wood Energy Workshop - Belgrade, Serbia 65Tuloskalvosarja
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Long-distance transportation of loose residues
Photos: Metsäteho Oy, UPM Forest
Wood Energy Workshop - Belgrade, Serbia 66Tuloskalvosarja
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Long-distance transportation of stumps
Photos: UPM Forest
Wood Energy Workshop - Belgrade, Serbia 67Tuloskalvosarja
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Conclusions• Several factors determine which forest chip
supply chain is used:Harvesting conditions, Roadside landing capacities, Road transportation distances, Operating volumes and storage capacities of energy plants, Availability of production machinery, The type of forest chips produced and, The total supply chain costs.
• There is not any universal supply chain!!!
Wood Energy Workshop - Belgrade, Serbia 68Tuloskalvosarja
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HvalaHvala mnogomnogo!!