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Collection of Forest ResiduesSpreading out of the bundling method
over Europe
Sylvain MARTIN,Area Manager, Latin Europe
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production• Bundling technology and method• Spreading out of the bundling method over Europe• French case study• Lessons learned and perspectives
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production• Bundling technology and method• Spreading out of the bundling method over Europe• French case study• Lessons learned and perspectives
It all started with a blacksmith shop…
Integrity … Quality … Commitment … Innovation
Introduction to Deere & Company
• World’s leading producer ofagricultural and forestryequipment: machines, systemsand attachments
• 4th oldest industrial company inUS – 170 years
• 47,000 employees worldwide
Deere & Company 2006 Net Sales & Revenues: $22.148 Billion
Commercial & Consumer 18%
Agricultural 46%
Credit 8%Construction &Forestry 26%
Other 2%
John Deere Forestry
• World’s premier producer of Forestry Equipment• Industry widest product range and distribution network
• CTL Technology center and manufacturing in Finland• FT technology and manufacturing in United States• Waratah attachments manufacturing in New Zealand• Over 1800 employees around the world
Full Tree method (FT) Cut-To-Length method (CTL)
Mannheim, Germany
Richards Bay, South AfricaNigel, South Africa
Pune, India
Beijing, ChinaJiamusi, China
Stadtlohn, GermanyGummersbach,Germany
Horst, NetherlandsEnschede, Netherlands
Bruchsal, GermanyZweibruecken, Germany
Arc-les-Gray, France
Saran, France
Madrid, SpainSantiago, ChileCatalao, Brazil
Horizontina, Brazil
Rosario, Argentina
Saltillo, MexicoMonterrey, Mexico
Torreon, Mexico
Valley City, ND
Fargo, NDMinneapolis, MN
Dubuque, IAHoricon, WI
Waterloo, IA
Moline, ILEast Moline, IL
Welland, Ontario
Edmonton, Alberta
Davenport,IA
Des Moines, IA
Langley, British Columbia
Ottumwa, IASpringfield, MO
Coffeyville, KS
Thibodaux, LA
Fuquary-Varina, NC
Greeneville, TN
Augusta, GA
Kernersville, NC
Santo Angelo, Brazil
Joensuu, FinlandWoodstock, Ontario
Rock Valley, IAKlemme, IA
Melbourne, Australia
Tokoroa, New Zealand
*
Tianjin, ChinaPiqua,OH
Poznan, Poland
John Deere Manufacturing units over the world
Presentation plan
• Introduction to Deere & Company
• Forest biomass procurement for energyproduction
• Bundling technology and method• Spreading out of the bundling method over Europe• French case study• Lessons learned and perspectives
Within the development of a procurement chain for energyproduction, several parameters must be kept under control
Logging, collection and transformation / communition costs
Transportation costs
Storage and handling costs
Raw material quality (caliber, cleanliness, energy content /humidity level)
Minimum and maximum procurement cycle times to be put in linewith energy production needs (normal period, peaks period,seasons)
Forest biomass procurement for energy production(1)
• One of the biggest problems in energy production lays in theimpossibility to store the energy once it has been produced.
• One solution can be found when looking at earlier phases in theproduction system – more precisely within the procurement processof the fuel itself, when storing biomass.
• Transportation and inventory costs are partially related to thevolume that is transported or stored (density, format, handlingrestrictions when storing), and to transportation distances.
Forest biomass procurement for energy production(2)
When collecting forest residues, theformat chosen for the transportationand storing of biomass has a great
influence on the later processphases!
Forest biomass procurement for energy production(3)
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production
• Bundling technology and method• Spreading out of the bundling method over Europe• French case study• Lessons learned and perspectives
Bundling Technology and method
Bundling - an integrated process
Compression unit at a glance
1 432 5
1- compression rollers (2V + 2H)2- compactor 2 (4s > 8s)3- compactor 3 (4s > 6s)4- binding unit + twine magazine5- saw unit
Bundling – a very efficient technology (1)
Bundling – a very efficient technology (2)
The bundling process makes slash logs from logging residuesIt is applicable to softwood and hardwood, dry or fresh residues
Weight per bundle: 350 to 700 kg (average 500 kg, with fresh material)
Compression ratio: approx. 80% of initial loose volume
Productivity: 20 to 40 pcs / hour (average 25-30 pcs, depending on site)
Length: 2 to 4 m long (mostly 2,5 or 3m)
Diameter: 0,6-0,8 mEnergy content = 1 MWH
Bundling – a very efficient technology (3)
Bundling method brings benefits at all levels!
Slash logs are very compact
Slash logs are homogeneous and hard to break
Easy to forward
They fit perfectly to the local logistic chains
Easy storage
Once piled at the road side, bundles dry naturally and do not require anyparticular handling or covering action – they greatly simplify the logistics!
Easy transportation by truck
The high density and suitable format enable an efficient loading.Bundles help rationalizing the transportation phase, which is generally themost expensive one throughout the whole procurement process!
Easy transportation by train
Easy handling at the plant
Enables Just in Time delivery of quality chips right in the forest…
… or at the mill
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production• Bundling technology and method
• Spreading out of the bundling methodover Europe
• French case study• Lessons learned and perspectives
Spreading out of the bundling method over Europe (1)
The bundling technology was invented in the late 90’s in southSweden, close to Växjö, by two entrepreneurs – Jan Carlsson andChrister Lennartsson, co-founders of the Fiberpac company.
At that time only 2 prototypes had been built – 1 in Sweden and theother 1 in UK.
At the occasion of the Forenergy European research project(2001-2004) – which was coordinated by Timberjack, the Fiberpac370B bundler was tested successfully under very differentconditions, in several western and southern European countries:France, Spain, Portugal, Italy, Austria, Germany, …
Softwood bundles, maritime pine - France
Hardwood bundles, dry chestnut - France
Hardwood bundles, fresh hornbeam - France
Hardwood bundles, dry eucalyptus - Spain
Spreading out of the bundling method over Europe (2)
During the year 2002, after having distributed and marketed it for 2years, Timberjack acquired all the rights of the Fiberpac 370B.
Later in this same year, the Fiberpac was further developed andbecame fully integrated to the Timberjack CTL product range as the1490D slash bundler.
By the end of 2002, some 24 bundlers were at work, mainly inFinland
During the 3-years span of the Forenergy project, the number ofunits at work kept on increasing steadily: 2 units were sold inSpain, 1 in Italy, 1 in Switzerland, 1 in Czech republic…
Altogether, nearly 35 units were working by the end of 2004.
1490D making Poplar bundles - Northern Italy
1490D at cable yarding operations - Austria
Hardwood bundles, fresh eucalyptus - Spain
Hardwood bundles, fresh eucalyptus - Spain
Spreading out of the bundling method over Europe (3)
By the end of 2007, more than 65 bundlers will have been deliveredby John Deere Forestry in Europe, including the first Fiberpac units.Everyday they will produce high quality slash logs – from North toSouth, East to West, representing some 3,6 million bundles perannum
The compacting unit has been adapted to trucks or trailers foralpine operations
It has also been modified to offer the possibility to the owner toremove it and use the base machine as a normal forwarder if theactivity level or season requires it. This is the so-called adapterversion.
Truck mounted bundler in Swiss alps
Same truck mounted unit in Hungary
Trailer mounted unit in the Carpat mountains
Latest 1490D ECO III – standard model
Latest 1490D ECOIII - bundler adapter model
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production• Bundling technology and method• Spreading out of the bundling method over Europe
• French case study• Lessons learned and perspectives
French case study
Figures from the past vs. estimate for the present
• According to the studies made in 2002 during the Forenergy tests in
France, the minimum production with the Fiberpac 370B was 5 T/h and
the maximum 8,5 T/h, i.e. respectively 12 to 21 bundles / h
(under French conditions).
• A realistic estimate was made later in 2006, when the first 1490D was
sold to France. This estimate showed that with the latest evolution of
this technology, a production of 18 to 25 bundles/h could be expected,
i.e. 12.500 to 16.500 T/ year, once passed the learning phase and as
long as the way of operating the machine and planning the site would
be done properly.
Start-up of the first French unit - May 2006, Lorraine
The learning curve
• Two brothers have been driving this unit from the beginning – bothbeing quite skilled and experienced operators on forwarders andharvesters.
• 3 days of start up training were given by a Swedish operator at thedelivery of the unit and 2 more days were organized 8 months later,as an advanced training, with a Finnish operator
• During the first 6-7 months, this unit was working mainly on largerlogging sites (8-10 hectares) that were not necessarily plannedfor biomass collection from the beginning
• The production was in average between 100 and 130 bundles perday, in 1 shift. Downtime was relatively high for this machine,considering the operator had to change the chain of the sawing unitalmost every 1,5 hours due to a poor quality of the residues.
Poor quality material means downtime !
Facts from the field
• Just prior to receiving the second part of the operator training, inmarch 2007, this machine was moved 200km to the south from itsoriginal working area for 2 months, because of too wet conditions inthe north. There the sites were much smaller (1 to 2,5 hectares)but planned for biomass recovery.
• It turned out very quickly that the production rose up to 180-210bundles per day (1 shift). In fact the material was put in nice pilesby the harvester operator and therefore the branches being cleaner,the operator didn’t have to change the chain so often.
Example of proper piles
Operator training and proper adjustments matter too!
• At the occasion of the advanced training given by the Finnishoperator, machine settings were adjusted so that boom speedwas decreased to a certain extent and saw motor speed waslowered slightly.
• The first change made the collecting and feeding movements alot more fluent and efficient, but not really slower.
• The second change helped to decrease even further the cross-cutting time of a bundle, taking it down to 6-7 seconds vs. 15-20swith improper settings or damaged chain.
• Soon after this training, the 2 brothers recorded their best-everproduction peak of 350 bundles in a 9-hours shift, with theaverage production being in the range of 240-270 bundles per day,i.e. 33 to 38 bundles / hour, when the residue piles are well prepared
Organization is accountable for more than50% of productivity with the bundling method!
French experience as of today
• 3 bundlers are working at the moment in France,• a 4th one is planned for delivery in the near future• 2 or 3 projects should move to realization phase
within the next 12 months• It takes time to change the mentality of people:
contractors, foresters and forest owners, paperindustry, board industry and saw mills…
• Some “outsiders” will enter the bioenergy productionmarket and will change the rules and habits
Presentation plan
• Introduction to Deere & Company• Forest biomass procurement for energy production• Bundling technology and method• Spreading out of the bundling method over Europe• French case study
• Lessons learned and perspectives
Lessons learned and perspectives
Considering the wide diversity of the conditions that can be found inEurope, it is necessary to look for a maximum of flexibility:
– Flexibility with regards to the residue collection method(depending on tree species, on geographical situation, surface /volume of biomass available, on season)
– Flexibility with regards to the highly variable procurementdistances. Depending on distances, selected strategies willhave to be adapted (terminal, transportation by truck, train,boat...)
– Flexibility to fit as good as possible in the existingprocurement chains and benefit as much as possible of leverswith logistics tools available nowadays (GIS and planning tools)
NB: there is no unique or perfect system!
An holistic approach
• A global approach needs to be utilized in order to establish asmuch synergies as possible between the existing traditionalindustries and the fast growing energy wood industry> do not think about 1 + 1 system, but rather 1 total system
• This global approach is necessary, right from the beginning of theharvesting planning of a given site
• All stakeholders must play the game and be committed
Once again, there is no unique or perfect system andtechnology alone will not bring you success in the bioenergybusiness
Thank you for your attention
Nothing Runs Like a Deere™
