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

Structural Use of HardwoodsStructural Use of HardwoodsStructural Use of Hardwoods

FingerFinger--Jointed StudJointed Stud

Ponderosa Pine GlulamPonderosa Pine Glulam(Egar, AZ)(Egar, AZ)

• 100% pine100% pine

•• 50% stronger50% stronger

•• 20% stiffer20% stiffer

EE--ratingrating

Traditional UsesTraditional Usesfor Roundwood for Roundwood Less Than Less Than 8 In.8 In.

•• 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

Porterbilt Post & PolePorterbilt Post & Pole(Hamilton, MT)(Hamilton, MT)

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

Jefferson State Jefferson State Forest ProductsForest Products

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

““Sonoboard” Conference Table Sonoboard” Conference Table by Sonocoby Sonoco

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

WoodWood––Plastic Plastic CompositesComposites

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

Wood Fiber MatsWood Fiber Mats•• Erosion controlErosion control

•• Water filtersWater filters

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

Small CommercialSmall CommercialBioenergy SystemBioenergy System

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.

North Park High School (Greenhouse)North Park High School (Greenhouse)(Walden, CO)(Walden, CO)

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)

Darby, MTDarby, MT

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 constructionslevan@fs.fed.us

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

slevan@fs.fed.uswww.fpl.fs.fed.us/tmu