Opportunities for Using Thinnings from Forest Fuel-Reduction
Activities
Opportunities for Using Thinnings from Forest Fuel-Reduction
Activities
S&PF Technology Marketing UnitUSDA Forest Service
Forest Products LaboratoryMadison, WI
S&PF Technology Marketing UnitUSDA Forest Service
Forest Products LaboratoryMadison, WI
Technology Marketing UnitTechnology Marketing Unit
Develops new technologiesDevelops new technologies
Coordinates needs with FPL/FS ResearchCoordinates needs with FPL/FS Research
Provides technical assistanceProvides technical assistance
Demonstrates valueDemonstrates value--added opportunitiesadded opportunitiesin rural communities in rural communities
Provides a clearinghouse of informationProvides a clearinghouse of information
Facilitates networkingFacilitates networking
Current Market Values forCurrent Market Values forSmallSmall--Diameter TreesDiameter Trees
0
50
100
150
200
250
Valu
e ($
/gre
en to
n)
Poles Posts Lumber Firewood Chips
Cost toharvest
Fuel Reduction Treatments forFuel Reduction Treatments forPonderosa Pine on Gentle SlopesPonderosa Pine on Gentle Slopes
+ 465- 975590Rockies
+ 615- 1,138600Sierras
+ 433- 1,090630Inter-mountain
+ 496- 1,176680Southwest
Higher value Chipped
Net revenue ($/acre)if larger trees are
Gross removal
costs($/acre)
Location
www.fs.fed.us/research
Products of Primary ProcessingProducts of Primary Processing
SawlogsSawlogs•• Structural lumberStructural lumber•• Nonstructural lumberNonstructural lumber
RoundwoodRoundwood•• Poles/postsPoles/posts•• Logs for log homesLogs for log homes
ChipsChipsResiduesResidues
Traditional Log ProcessingTraditional Log Processing
In the West, logs are generally In the West, logs are generally 8 inches and larger8 inches and larger
Specialized equipment (smallSpecialized equipment (smalllog processors) for logs down log processors) for logs down to 6 inches in diameterto 6 inches in diameter
Applies to both hardwoods andApplies to both hardwoods andsoftwoodssoftwoods
ValueValue--Added ProductsAdded ProductsEngineered wood Engineered wood productsproducts
FlooringFlooring
PanelingPaneling
CabinetsCabinets
FurnitureFurniture
MillworkMillwork
Ponderosa Pine GlulamPonderosa Pine Glulam(Egar, AZ)(Egar, AZ)
• 100% pine100% pine
•• 50% stronger50% stronger
•• 20% stiffer20% stiffer
EE--ratingrating
•• Reduce processing costs Reduce processing costs •• Less susceptible to warpLess susceptible to warp•• Graded logs may have a higher valueGraded logs may have a higher value•• Logs should be dryLogs should be dry
Expanding Expanding Markets Past Markets Past Posts & PolesPosts & Poles
Round structural beamsRound structural beams
Engineered Engineered Roundwood Roundwood StructuresStructures
Standard designsStandard designs
Demonstration projectsDemonstration projects
Market size assessmentMarket size assessment
Material propertiesMaterial propertiesStructural gradingStructural gradingsystemssystemsConnection designsConnection designs& analysis& analysisEngineeringEngineering
Olympic KioskOlympic Kiosk((Ogden Ranger District)Ogden Ranger District)
•• Lodgepole pineLodgepole pine(Bitterroot NF)(Bitterroot NF)
•• 66--in. verticalsin. verticals•• 44-- & 5& 5--in. trussesin. trusses
•• 40 by 60 ft40 by 60 ft•• PonderosaPonderosa
pinepine•• 66--in. verticalsin. verticals•• 44--in. trussin. truss
membersmembers
Park PavilionPark Pavilion((Westcliffe, COWestcliffe, CO)
LibraryLibrary((Darby, MT)Darby, MT)
•• Lodgepole pine Lodgepole pine (Bitterroot NF)(Bitterroot NF)
•• 66--in.in.--diameter logsdiameter logsfor the trussesfor the trusses
•• CrossCross--country skiingcountry skiing•• Trail groomingTrail grooming•• Ski PatrolSki Patrol
•• Ponderosa pinePonderosa pine•• 55-- to 6to 6--in. membersin. members
Salt Creek SummitSalt Creek Summit(La Grande, OR)(La Grande, OR)
Cable Suspension BridgeCable Suspension Bridge
Traveler’s Rest State ParkTraveler’s Rest State Park(Lolo, MT)(Lolo, MT)
Removing Technical BarriersRemoving Technical Barriers
Mechanical gradingMechanical gradingPowderPowder--drivendrivenfastenerfastener
Round PostRound PostGuardrailGuardrailSystemsSystems
Structural gradingStructural grading
Dynamic testingDynamic testing
Crash testingCrash testing
Jefferson State Jefferson State Forest ProductsForest Products
(Hayfork, CA)(Hayfork, CA)
Technical assistanceTechnical assistance• Kiln dryingKiln drying•• Processing for figureProcessing for figure•• Steaming madroneSteaming madrone
Pulp Pulp Wood compositesWood compositesWoodWood––plastic compositesplastic compositesWoodWood––concrete productsconcrete productsWood fiber productsWood fiber products•• Erosion control matsErosion control mats•• Water filtersWater filters
Chips/StrandsChips/Strands
Pulp ChipsPulp Chips
Traditional marketTraditional market
Pulp prices downPulp prices down
Global overcapacity Global overcapacity
Transportation costsTransportation costs
33--DDPulpPulp--Molded Molded
ProductsProducts
Made like corrugated Made like corrugated paperpaperFibers aligned for Fibers aligned for strengthstrengthHalf the weight of Half the weight of particleboardparticleboard
Patented by FPLPatented by FPLLicensed by Sonoco Licensed by Sonoco for laminated furniturefor laminated furniture
Wood CompositesWood Composites
Lots of opportunities for useLots of opportunities for use•• Particleboard, fiberboardParticleboard, fiberboard•• Oriented strandboardOriented strandboard
Capital intensiveCapital intensiveDependent on reliable supplyDependent on reliable supplyIndustry shifting to East and Industry shifting to East and SouthSouth
WoodWood––Plastic CompositesPlastic Composites
Offer opportunities on smaller scaleOffer opportunities on smaller scale
Can be configured to meet regional Can be configured to meet regional needsneeds
Localized applications using local Localized applications using local problematic resourceproblematic resource
$900 million market expected$900 million market expected
Technical Assistance on Technical Assistance on Prototype DevelopmentPrototype Development
P&M SignsP&M Signs(Mountainair, NM)(Mountainair, NM)
•• Juniper / plasticJuniper / plastic
•• 50% juniper &50% juniper &50% polyethylene50% polyethylene
•• 30% juniper &30% juniper &70% polyethylene70% polyethylene
Invasive SpeciesInvasive Species
SidingSiding(Boise’s (Boise’s HomePlateHomePlate™™))
Roof shakesRoof shakes
AdditionalAdditionalWoodWood––Plastic Plastic ApplicationsApplications
WoodWood––ConcreteConcreteProductsProducts
•• Reduces weightReduces weight
•• Improves soundImproves soundabsorptionabsorption
•• Playground surfacePlayground surface
•• ADA complianceADA compliance
WoodWood––LatexLatexProductsProducts
Water FiltrationWater Filtration
Use withUse with•• Storm waterStorm water•• Ag. runoffAg. runoff•• Mining sitesMining sites
Can removeCan remove•• Heavy toxic Heavy toxic
metalsmetals•• OilOil
Removing Toxic Heavy MetalsRemoving Toxic Heavy Metals
•• Applicable toApplicable tomany species many species
•• Some better forSome better forcertain metalscertain metals
•• Cannot makeCannot makemats in woodsmats in woods
Water Filtration on the Water Filtration on the Wayne National ForestWayne National Forest
23853.2After 2nd
filter
21723.1After doser
292.7After 1st
filter
----2.7Mining head
AluminumIron
% Metal removed
pHLocation
Erosion Control MatsErosion Control Mats
•• Use wood fiberUse wood fiber–– Live treesLive trees–– BurnedBurned–– Insect killedInsect killed
•• Local applicationsLocal applications•• BiodegradableBiodegradable•• Low capitalizationLow capitalization
costscosts•• InIn--woods processingwoods processing
Residues
Animal beddingAnimal bedding
CompostCompost
MulchMulch
EnergyEnergy
EthanolEthanol
FirewoodFirewood
Wood Shavings for Animal BeddingWood Shavings for Animal Bedding
•• Material from Material from hazardous fuelshazardous fuelsreductionreductionprojectsprojects
•• Understand theUnderstand thecustomer’s needscustomer’s needs
SBS Wood ShavingsSBS Wood Shavings(Ruidoso, NM)(Ruidoso, NM)
Biomass EnergyBiomass EnergyHuge potential for using thinningsHuge potential for using thinningsThermal, electrical, and biofuel (ethanol)Thermal, electrical, and biofuel (ethanol)Scale is importantScale is important
•• Large (>5 megawatts)Large (>5 megawatts)–– High cost, high efficiencyHigh cost, high efficiency
•• Medium (1 to 5 megawatts)Medium (1 to 5 megawatts)•• Small (<1 megawatt)Small (<1 megawatt)
–– Lower cost, less efficient, inLower cost, less efficient, in--woods woods processingprocessing
Energy still lowest economic valueEnergy still lowest economic value
WholeWhole--tree chips: 4,500 Btu/lbtree chips: 4,500 Btu/lb•• Electric power generationElectric power generation•• SourceSource
−− Bole chips (uniformity)Bole chips (uniformity)−− Entire treeEntire tree
Mill chips/slabs: 5,100 Btu/lbMill chips/slabs: 5,100 Btu/lbPellets (highest cost): 8,200 Btu/lb Pellets (highest cost): 8,200 Btu/lb Firewood (seasoned): 20 million Btu/cordFirewood (seasoned): 20 million Btu/cordSawdust (green vs. dry)Sawdust (green vs. dry)Bark (more energy vs. more difficult handling)Bark (more energy vs. more difficult handling)
Commercial Wood FuelsCommercial Wood Fuels
ElectricityElectricityHeat (steam, hot water)Heat (steam, hot water)Cooling (air conditioning)Cooling (air conditioning)Wood gas (crop drying, dualWood gas (crop drying, dual--fuel)fuel)BioBio--fuelsfuels•• BioBio--ethanolethanol•• BioBio--oiloil•• BioBio--methanolmethanol•• BioBio--dieseldiesel
Commercial Wood FuelsCommercial Wood Fuels
ElectricityLarge Scale ( >10 MWe )
ElectricityElectricityLarge Scale ( >10 MWLarge Scale ( >10 MWe e ))
Steam boiler/turbineSteam boiler/turbine•• Several facilities across the country Several facilities across the country
coco--fire with coal (5% to 15% wood)fire with coal (5% to 15% wood)
•• McNeil Power Plant: 50 MWMcNeil Power Plant: 50 MWee
•• Ryegate: 20 MWRyegate: 20 MWee
•• District Energy of St. Paul: 25 MWDistrict Energy of St. Paul: 25 MWee(all urban tree waste)(all urban tree waste)
District EnergyDistrict Energy(St. Paul, MN)(St. Paul, MN)
• Urban wood wasteUrban wood waste
•• DaytimeDaytime–– Heating & coolingHeating & cooling
to downtownto downtown–– Electricity to gridElectricity to grid
•• NightNight–– Cooling downtownCooling downtown–– Uses electricityUses electricity
LargeLarge--Scale Power GenerationScale Power GenerationUsually uses coal or natural gasUsually uses coal or natural gasAll forms of energy have common All forms of energy have common problems. Favorable purchase agreement problems. Favorable purchase agreement must cover the following costs:must cover the following costs:
•• Harvesting Harvesting •• TransportationTransportation•• Power generationPower generation•• Power distributionPower distribution
To date, purchase agreements do not To date, purchase agreements do not cover development & production costscover development & production costs
SmallSmall--Scale Wood CombustionScale Wood Combustion
Typical featuresTypical features•• 3 million Btu/hour (900 kW) output3 million Btu/hour (900 kW) output
•• 850 lb/hour (green) fuel input850 lb/hour (green) fuel input
•• 45% moisture content (wet basis)45% moisture content (wet basis)
•• 20:1 turndown ratio20:1 turndown ratio
(Divide the maximum energy output by the (Divide the maximum energy output by the minimum energy output at which efficient, minimum energy output at which efficient, smokesmoke--free combustion can be sustained.)free combustion can be sustained.)
Audience for SmallAudience for Small--Scale Scale CombustionCombustion
Who can use the system?Who can use the system?•• Companies where electricity costCompanies where electricity cost
for heating is highfor heating is high•• Companies that generate biomass onCompanies that generate biomass on--sitesite
Considerations and complexitiesConsiderations and complexities•• Physical sizePhysical size•• Fuel characteristicsFuel characteristics•• OperationOperation•• Mechanical complexityMechanical complexity•• Combustion hazardsCombustion hazards
Institutional UsesInstitutional Uses
SchoolsSchoolsFactoriesFactoriesHospitalsHospitalsState buildings (Vermont)State buildings (Vermont)Community centersCommunity centersJails/prisonsJails/prisons
Cost of Small ScaleCost of Small ScaleInitial capital costsInitial capital costs
•• $50 to $75 per lb of steam generated per hour$50 to $75 per lb of steam generated per hour•• Biomass system capital costs highest of any Biomass system capital costs highest of any
fuel (typically 1.5 to 4 times the cost of fossil fuel (typically 1.5 to 4 times the cost of fossil fuel)fuel)
–– FuelFuel--handling systemhandling system–– Fuel storageFuel storage–– Low energy density fuelLow energy density fuel
Annual cost Annual cost •• Full life cycle vs. payback (advantageFull life cycle vs. payback (advantage--wood)wood)•• Wood is typically cheapest fuel available Wood is typically cheapest fuel available
Costs for New ConstructionCosts for New Construction
100,000 100,000 –– 150,000 ft150,000 ft²²
Wood energy system:Wood energy system: $ 220,000$ 220,000Building construction:Building construction: 150,000150,000
Design:Design: 30,00030,000
Total:Total: $ 400,000$ 400,000
UnionUnion--32 School32 School(East Montpelier, VT)(East Montpelier, VT)
Total installed cost: $325,000 (200,000 ftTotal installed cost: $325,000 (200,000 ft22))
Total heating capacity: 4.5 million Btu/hTotal heating capacity: 4.5 million Btu/h(1.35 MW)(1.35 MW)
Fuel quantity: ~1000 tons of green chipsFuel quantity: ~1000 tons of green chipsper year ($30/ton)per year ($30/ton)
75% system efficiency: $0.20 per ft75% system efficiency: $0.20 per ft22
annuallyannually
WoodWood--Fired Chiller for SchoolsFired Chiller for Schools
Wood residue as fuelWood residue as fuelHot water boilerHot water boiler
•• Silica gel adsorption process: nontoxic Silica gel adsorption process: nontoxic •• Low temperature: 122Low temperature: 122ººF to F to 194194ººF supply F supply
waterwater
1/5 the cost of electricity 1/5 the cost of electricity –– 400 ton unit400 ton unit•• $ 25 to $ 30 per ton wood @1 ton/h$ 25 to $ 30 per ton wood @1 ton/h•• $ 0.08 per kWh @1500 kWh$ 0.08 per kWh @1500 kWh
(12,000 Btu/h cooling capacity is equivalent to 1 ton of refrige(12,000 Btu/h cooling capacity is equivalent to 1 ton of refrigeration.)ration.)
Memorial Medical CenterMemorial Medical Center(Ashland, WI)(Ashland, WI)
Hospital size: 3 floors; 210,000 ftHospital size: 3 floors; 210,000 ft22
125 HP boiler system; 5.16 million Btu/hr 125 HP boiler system; 5.16 million Btu/hr Fuel requirement Fuel requirement
•• 3,000 to 3,800 tons per year3,000 to 3,800 tons per year•• Truckload delivery every other dayTruckload delivery every other day
Source of fuel: wood chips from Source of fuel: wood chips from hardwood manufacturing facilityhardwood manufacturing facility
SteamSteam•• UsesUses
–– HeatingHeating–– Air conditioningAir conditioning–– Process steam Process steam
(sterilization)(sterilization)•• Costs of producingCosts of producing
–– Wood fuel: $0.08/lbWood fuel: $0.08/lb–– Gas: $0.28/lbGas: $0.28/lb
Memorial Medical CenterMemorial Medical Center(Ashland, WI)(Ashland, WI)
National SmallNational Small--Scale BiomassScale BiomassDemonstration ProjectDemonstration Project
Partnered with Partnered with
•• U.S. Department of Energy, U.S. Department of Energy, National Renewable Energy National Renewable Energy Laboratory, Golden, COLaboratory, Golden, CO
•• Community Power Corp., Community Power Corp., Littleton, COLittleton, CO
BioMax 15 is a prototype BioMax 15 is a prototype gasification unit that burnsgasification unit that burnswaste wood to create electricity waste wood to create electricity (15(15--20 kW). Installed at SBS Wood 20 kW). Installed at SBS Wood Shavings, October 29, 2002.Shavings, October 29, 2002.
BioMax 5BioMax 5Residential ApplicationResidential Application
•• Electricity 24/7Electricity 24/7–– Unit chargesUnit charges
batteriesbatteries–– Automatic Automatic
shutdownshutdownwhen fully when fully chargedcharged
•• Heat for hot waterHeat for hot water
Research DemonstrationResearch DemonstrationHouse at FPL (House at FPL (Madison, WI)Madison, WI)
Fuels for SchoolsFuels for SchoolsWood chips (forest slash) replacing fuel oil
500 green tons of wood per year
82,000 ft2 heating space
150 HP (5 million Btu/h)
Low pressure steam (15 psig)
Messersmith Industrial Combustion
•• Funded economic and engineeringFunded economic and engineering
•• Provided technical information about biomass Provided technical information about biomass energy so community could make informed energy so community could make informed decisions decisions
•• By demonstrating the Darby system as a viable By demonstrating the Darby system as a viable heating source, it is hoped that other Montana heating source, it is hoped that other Montana schools will develop interest schools will develop interest
Assistance to Darby Assistance to Darby SchoolSchool
•• Contributes to hazardous fuelContributes to hazardous fuelreduction on forested landsreduction on forested lands
•• Cuts heating fuel bill in halfCuts heating fuel bill in half•• Domestic source of energyDomestic source of energy•• Creates local jobs associated with thinning & Creates local jobs associated with thinning &
chippingchipping•• Releases only 3% of methane, 5% CO, and Releases only 3% of methane, 5% CO, and ⅓⅓ of of
NOx’s and particulates associated with burning NOx’s and particulates associated with burning slash pilesslash piles
Benefits to DarbyBenefits to Darby
Types of Log YardsTypes of Log Yards
Log sort & sale yardLog sort & sale yard
Mill log yardMill log yard
Reloading & concentration yardReloading & concentration yard
Interest in LogInterest in Log--Sort YardsSort Yards
Response to timber supply issuesResponse to timber supply issues
Land mangers need economicalLand mangers need economicalways toways to
•• reduce fuel loading in the Westreduce fuel loading in the West
•• market lowmarket low--value material from value material from thinning operations & restoration thinning operations & restoration projectsprojects
What Do LogWhat Do Log--Sort Yards Do?Sort Yards Do?
Concentrate, merchandise & sort Concentrate, merchandise & sort logs for higher valuelogs for higher value
Market multiple log productsMarket multiple log products
May include semiMay include semi--log processing log processing and valueand value--added operationsadded operations
Supply a more desirable log mixSupply a more desirable log mixto wood using firmsto wood using firms
Log Yard Primary ProductsLog Yard Primary Products
Sawlogs
Stud bolts
Peeler blocks
Veneer logs
Specialty logs
Poles
SemiSemi--processedprocessed& value& value--addedadded
PulpwoodPulpwood
FirewoodFirewood
Bark mulchBark mulch
Soil amendmentsSoil amendments
Biomass energyBiomass energy
Secondary & Residue ProductsSecondary & Residue Products
Peeled utility poles
Satellite chip mill
Log Sorting WithLog Sorting WithLog LoadersLog Loaders
Merchandiser & stationary Merchandiser & stationary loaderloader
RubberRubber--tire mounted loadertire mounted loader
CrawlerCrawler--track mounted track mounted heelheel--boom loader sortingboom loader sorting
a log decka log deck
Linear Log Sorting Machine Linear Log Sorting Machine
•• Low costLow cost
•• Sorts lengthSorts length
•• Sorts diameterSorts diameter
•• Does not sortDoes not sortfor sweepfor sweep
Small scaleSmall scale
Shipping Logs to MarketShipping Logs to Market
Rail reloading facility often economicalRail reloading facility often economical
SmallSmall--Log ProcessingLog Processing
Processing equipment & systems mustProcessing equipment & systems mustbe matched to the log resourcebe matched to the log resource
Large logs can be efficiently sorted & Large logs can be efficiently sorted & handled with a front end loaderhandled with a front end loader
Small logs require more specialized Small logs require more specialized loaders (heelloaders (heel--boom or knuckleboom or knuckle--boom)boom)
Really small logs require sorting machines Really small logs require sorting machines or merchandisers to be efficientor merchandisers to be efficient
SmallSmall--Log Processing Log Processing (con.)(con.)
Processing small logs requires very high Processing small logs requires very high piece count rates to be efficientpiece count rates to be efficient
Mobile log handling equipment is limited Mobile log handling equipment is limited by machine duty cycleby machine duty cycle
Log volume is really a function of machine Log volume is really a function of machine lifting capacitylifting capacity
Consequently, yard productivity is Consequently, yard productivity is controlled by piececontrolled by piece--count production rate count production rate rather than total log volume processedrather than total log volume processed
Where Can We ReduceWhere Can We Reduce& Control Costs?& Control Costs?
Cost of logs delivered to the yardCost of logs delivered to the yard•• Log stumpage priceLog stumpage price•• Harvest & stand treatment (thinning) Harvest & stand treatment (thinning)
costscosts•• Transportation costsTransportation costs
Log yard costsLog yard costs•• Processing & material handling costsProcessing & material handling costs•• Overhead & log inventory chargesOverhead & log inventory charges
MarketingMarketing——sell logs for higher pricessell logs for higher prices
Sort woods run logs into higher value logs Sort woods run logs into higher value logs
Merchandise logsMerchandise logs•• Buck & sort logs for higher valueBuck & sort logs for higher value•• Optimize log bucking & sorting decisionsOptimize log bucking & sorting decisions
SemiSemi--log processinglog processing
ValueValue--added manufacturingadded manufacturing
Raising the Value CurveRaising the Value Curve
Barriers to Successful OperationsBarriers to Successful OperationsPoor markets
• Lack of regional manufacturing capacity• Poor transportation infrastructure• Global competition
The wrong methods & machinesLack of reliable raw material sourceNot enough high-value logs in log mixLack of experienced sort yard operators
TMU StaffTMU Staff
Sue Sue LeVanLeVan--GreenGreenProgram Manager
Rick BergmanRick BergmanBiomass energy & TMU website
John John ZerbeZerbeBiomass energy & recycling
Rusty DrammRusty DrammForest products utilization
Gerry JacksonGerry JacksonMarketing
Mark KnaebeMark KnaebeFinishing & roundwood [email protected]
www.fpl.fs.fed.us/tmu
TMU StaffTMU Staff
Jean LivingstonJean LivingstonWriting & publicity
Adele OlstadAdele OlstadTechlines, FPC&R Review
Chris CaldwellChris CaldwellStudent
Dean GrahamDean GrahamTechnical assistance for Regions 1&4
Tommy Tommy LogginsLogginsTechnical assistance for Region 8
VacantVacantTechnical assistance for Regions 5&6
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