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Analysis of modern wood processing techniques in timber terminals

Analysis of modern wood processing techniques in timber terminals The transportation of forestry products is performed over long distances and is quite expensive, which limits the development of biofuel plants in Russia and around the world. The use of timber terminals contributes to transporta- tion cost reduction and mitigates negative environmental impacts. This work aims to analyze various technological solutions for optimization of forestry products processing at temporary terminals and cost reduction of transporta- tion, shipping, and wood treatment. The work presents a discussion on the technological and economic possibilities of the mobile pellet plant, the mobile essential oil production plant, and an enhanced autonomous electric generator system. It is shown that the use of mobile plants for obtaining pellets and essential oils allows processing wood residues at the terminal, which reduces the cost of transportation and shipment of raw materials and improves the quality of the finished products. The current study also examines some of the modern scanning technologies used to detect log defects and obtain complete biometric information in real time while assessing the productivity of wood processing operations. The results of the study can be used to develop efficient movable timber terminals. Key words: energy wood; equipment; fuel; storage location; supply chain Editor: Bohdan Konôpka ment of quality roundwood in the developed commercial 1. Introduction forests and the associated continued growth of the log- With the aim of reducing the impact of human activities ging transportation arm, which has already exceeded on climate change and environmental ecology in the glo- 300 km in Siberia and the Far East (Lobovikov & Pry- bal community, different actions to reduce the extraction adilina 2020; Likhouzova & Demianova 2021). Mature of fossil energy resources and the transition to renew- and over-mature forests in proximity to the main wood able energy sources in the production and transmission processing centers, often remain only in less developed processes have been undertaken (Dogaru 2020; Halkos swampy or heavily rugged areas (Mokhirev & Goryaeva & Gkampoura 2020; Morita et al. 2002). The success of 2017). The growth of the harvested timber transportation such a transition depends on optimizing the supply of arm along with an increase in the specific fuel consump- renewable raw materials, developing competitive pro- tion for the transportation of a depleted cubic meter of duction systems, and long-term regulation to compete wood and the specific depreciation of wood trucks leads against fossil fuel products (Giuliano et al. 2016). to a significant increase in the cost of harvested timber. Currently, there is an excess of forest biomass in It is associated with the need to finance the building and Northern European and Russian countries, which maintenance of an extensive network of forestry roads. includes discarded wood, forest residues, branchwood, and stumps (Athanassiadis & Nordfjell 2017). In the Rus- At the same time, the prospects for offsetting the costs sian forestry sector, there has been a gradual impoverish- of developing a network of forest roads for forest users *Corresponding author. Oľga Kunickaya, e-mail: olkunickaya67@rambler.ru O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 are still not developed (Kozlov et al. 2019). Despite the (2021) held a meeting of the subcommission on customs- comparatively low payment rate for forest resources in tariff, non-tariff regulation, and protective measures in Russia, timber harvested from natural forests is becom- foreign trade, at which it was decided to introduce a tem- ing less and less competitive in terms of production costs, porary two-year restriction on the export of veneer blocks. which is illustrated in Fig. 1. The study of the situation with raw materials at Russian veneer enterprises showed a negative trend in the supply of veneer logs to processing industries and an increase in exports of these raw materials to China. For a while, this has helped mitigate the shortage of raw materials for domestic veneer enterprises, but it is only a reprieve. This is largely due to the incorrect policy in the field of reforestation and the absence of a policy on the cultiva- tion of deciduous plantations of seed origin (Kuzminyh et al. 2020; Uvsh et al. 2020). The solution for this problem might be the development of the target cultivation (plant- ing) of wood, as is accepted in most countries of the world (Bulat et al. 2017; Kemppinen et al. 2020). Currently, the most requested round woods in Rus- sia are conifer logs (diameter, 14–38 cm), balance logs (diameter, 6–24 cm), and plywood logs (diameter, 18 cm onwards). There is also a problem of low-quality wood Fig. 1. Indufor analysis of sawn logs costs (InduforGroup accumulation on the rental bases of forest companies that 2021). require extensive development and implementation of technological processes for effective wood processing. Moreover, the ongoing removal of forest harvest- It is needed, at least, to ensure that the added value of ing sites for mature and overmature stands away from products derived from such timber covers the costs of the personnel residences of forest companies (sites) its harvesting (Loučanová et al. 2017). To address this leads to increased use of shift logging methods. In turn, issue in Russia, government strategies for collecting and it is associated with establishing shift work camps and some processing non-wood (food) forest products have been infrastructure of their service, which also increases the cost of adopted since 2009. However, this process calls for very harvested wood (Tambi et al. 2017). The cost structure for specific machine and equipment systems. Besides, har- roundwood with its own leasing base is shown in Fig. 2. vested forest food products cannot be transported over The cost of wood harvesting can be reduced by opti- long distances. Such wood must be processed in the near- mal planning of transportation from the logging site est places to the logging sites and in the shortest possible (Mokhirev et al. 2019; Rudov et al. 2019). time in order to avoid significant quality loss (Lovrić et The difc fi ulties of forestry enterprises and the exhaus - al. 2020; Stryamets et al. 2020). tion of available quality resources of mature forests lead In the development of forest areas away from wood- to a shortage of wood raw materials for domestic wood processing sites, there is increasing use of the temporary processing enterprises. For example, in March 2018, the timber terminal principle. Timber terminals are tradition- Ministry of Industry and Trade of the Russian Federation ally used as storage and transshipment points for round- Fig. 2. Cost structure of roundwood in case of the own leasing base, RUB per m (Tambi et al. 2017). 52 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 wood within forest industry supply chains (Korpinen et efficient compared to direct raw material supply chains. al. 2018; Berg & Athanassiadis 2020). Currently, timber Furthermore, dust emissions and explosions, destruction terminals are primarily in place to facilitate the distribu- during storage, self-heating, and ignition are important tion of roundwood supply and processing. The principle criteria in the design of a terminal for wood pellet plants. of timber terminals placement in the leasing base under Also, it may signic fi antly affect related logistics. However, development is illustrated in Fig. 3. based on a review of existing technological solutions in The principle of temporary timber terminals based various European countries (Dafnomilis et al. 2018), on mobile wood processing equipment is the primary there is a small volume of wood pellet plants, but constant processing of harvested wood with the further produc- equipment modernization and the rebuilding of termi- tion of timber, the stacked-volume ratio of which is close nals contribute to increased volume of products received. Fig. 3. Principle of a temporary timber terminal establishment in the developed leasing base (Marques et al. 2012). to 100%. In the future, the wood obtained using mobile In addition to that, producing essential oils from timber sawmills can be treated with antiseptic, if necessary (for by-products, such as branches and shoots of spruce and example, during the warm season) and then exported to pine, at timber terminals can increase the output of essen- specialized sawmills for the final processing into high- tial oils without losing their valuable properties. Labokas quality sawn wood (Gedjo et al. 2020). Furthermore, et al. (2017) discovered that storage of pine leaves at cold wooden terminals may also be used to produce pellets temperatures has an adverse effect on the overall yield of and other products. For example, in many developed pine essential oils compared to when the leaves are fresh. countries, such as Japan and South Korea, there is a Therefore, developing a mobile system for producing trend towards decreasing the consumption of fossil essential oils is an urgent task. Consequently, it is impor- fuels and switching to renewable energy sources (Jafari tant to consider the operating and energy costs in plan- et al. 2020; Junginger et al. 2020). Japan has adopted ning and designing the terminals. The current state of a strategy that aims to increase pellet fuel consumption terminals and available modern technological solutions to 20% by 2030; as a result, the demand for this type of are of great relevance when it comes to process optimiza- product is constantly increasing (Pambudi et al. 2017). tion, and mobility/maintenance cost reduction. Timber The largest pellet supplier to these countries is Canada, terminals as temporary yards usually have no centralized which accounted for approximately 63% of pellet imports electricity generation. The use of internal combustion in 2015 (Ahl et al. 2018). In the European Union, there is engines as power stations considerably increases the cost a similar trend of utilizing wood pellets as fuel in thermal of wood processing, given that the cost of fuel is rather power plants and for building heating purposes (Daf- important and that the efficiency factor of internal com- nomilis et al. 2017). Given these trends, the demand for bustion engines is much lower than that of electric motors wood pellets will only grow bigger, which necessitates (Bhandari et al. 2015; Savelev et al. 2019). Besides, the the need to improve production processes and logistics transition from traditional to renewable energy sources in Russia to enable import to Europe and Asia. Virkkunen enables efficient use of technology with full processing et al. (2016) explored the cost-effectiveness of using ter- cycle of logging and wood industry waste. minals for biomass storage, processing, and fuel supply Modern energy can be characterized by tendencies to under any conditions in Finland. The study results on the diversify sources, increase autonomy, reliability, safety, costs for maintaining satellite terminals and developing environmental friendliness, and use of new materials forest fuel logistics showed that terminals are not more (Aruova et al. 2020). Alternative and renewable energy 53 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 sources include wind and hydroelectric systems, biogas 2. Technological and energy features plants, solar collectors, photovoltaic inverters, and heat of the mobile pellet line at timber terminals pumps for the extraction of low-potential heat from the For sawing up to 50 m of wood per shift, it is sufc fi ient to ground, water, and air (Vo et al. 2020). Another alter- equip the sawing terminal with a single-passage sawmill native source of electricity at mobile timber terminals with an energy consumption of about 37 kW. When saw- can be a gas generator (Tsyvenkova et al. 2020), which ing 80–210 m per shift, it is optimal to equip the timber uses waste (tree bark, branches, and stumps) from wood terminal with a mobile crossover line with feed speeds processing operations as fuel. The use of modern tech- up to 30 m per min. The electricity consumption of this nologies in material engineering (Pomiguev et al. 2018) line is approximately 340 kW. For 300 m per shift saw- makes it possible to increase gas generator’s efficiency, ing, the timber terminal is ideally to be equipped with a stabilize electricity generation from biofuels, and reduce mobile feeder with a speed of up to 50 m per min. The the size of the terminal for better transportation (Zagrut- power consumption of this line is approximately 750 kW dinov et al. 2017). In addition, timber by-products may be (Tambi et al. 2019). a basis for the production of many other products (e.g., The use of mobile granulation devices allows obtain- essential oils, pellets, and shavings), some of which can ing not only the thermal (electrical) energy but also the n fi d use in pharmaceutical, chemical and light industries. finished product in the form of pressed biofuel from the Main objective of this study is to analyze various mod- primary wood treatment at the terminal (Ghaffariyan et ern technologies and ways to optimize the structure of al. 2017). timber terminals. To this end, the work provides a review The dimensions of the mobile pellet line correspond of modern techniques and systems for processing logs to the dimensions of a 40- foot container (drying mod- and forestry materials to obtain high-quality products ule), an extended 20-foot container (pelletizingm odule), and reduce the cost of transporting raw wood and other and a 20-foot container (wood preparation module). The products through Russia. The results of the analysis of equipment of the modules is located on specially created waste-free production techniques and advices made power frames with landings for its installation on stand- based on them can be useful in designing timber termi- ard container trucks and the necessary slinging elements nals for better process optimization and to increase the for loading and unloading operations (Fig. 4). quality and range of timber products. To install the line on the top warehouse, a level horizon- tal platform with a specic fi load capacity of 1000 kg per m is required. The actual demand of the line is 250.0 kW with an installed power factor of 0.7. The use factor may vary depending on the feedstock properties (species Fig. 4. Mobile pellet line: a) in transport position; b) in working position (Tambi et al. 2019). 54 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 composition, incoming moisture, etc.). There are three ditions is not economically viable. The main expense is employees on duty handling the shift. the WG transportation to the processing site with an The time required to prepare the line for operation extremely low stacked-volume ratio in the truck. shall not exceed 20 hours. It consists of unloading the line Technological processes of logging operations with and installing the line modules, joining them together, the use of feller-buncher machines, tractors with bundle installing cyclones and gas ducts, which are in the trans- grapple, processors at the top storage, gasoline-powered port and working position, and connecting the line to the saws, and systems for skidding trees with crowns and power supply grids. The height of the line in the working delimbers at the top storage allow concentrating biomass position is increased by installing projecting elements of tree crowns, including WG, by the roadside. The use of (cyclones and gas lines) up to 5.6 m. The raw materials harvesters and forwarders allows collecting concentrated for production, the non-commercial wood up to 370 mm heaps of logging residues with special pickers, bringing in diameter, first arrives on the hydraulic trestle. Then, it them to the roadside. From there, a small mobile unit for goes to the wood splitter piece by piece with subsequent the distillation of essential oil will be located at the place cross-cutting of the tree-length log into pieces up to 0.5 of WG concentration near the road. m and their splitting. Afterward, the raw material is Wood from twigs and branches is intended to use as delivered by the conveyor belt on the chipper with further fuel, and the air from a battery-powered fan is used to delivery of the received wood chip to the hopper-feeder. cool down the isotropic mixture of water vapor and oil. Then, the disk separator sorts out the bark and other cas- The material is expected to be mounted on a car trailer. ual subjects (including stones), which should not go into Mobile facility for the production of essential oils further processing. The sorted chips go into the hammer under logging site conditions, Fig. 5, consists of steam grinder. Then, using a conveyor, the finished wood pulp generator, two distillation devices (reservoirs for WG), enters the heat generator and the rotating drying drum condenser, separating flask, and box for the equipment through a raw material dispenser. The dried wood gets used. The unit operates with a closed water cycle, sepa- into the pneumatic discharge cyclone and the hammer rating flask is used for steam production, which reduces grinder. Exhaust gases are discharged from the cyclone energy costs and improves the efficiency of essential through a flue gas vacuum through a stack into the oils. Equipment technology parameters are designed to atmosphere. After a hammer grinder, the groundwood operate at air temperatures between –10 °C and +20 °C. enters a pellet press by a cyclone. The finished granu - Technological characteristics of the unit are described lates are transported by a conveyor belt to the chiller and in Woodex (2020). then to the vibrating screen. Afterward, pellets ready to be sieved using a scraper conveyor enter for packaging. Unsorted pellets and dust after the chiller and vibrating screen are reoriented for granulation using the cyclones and pneumatic conveying system. The line is controlled using only one control panel. As an option, on request, the line can be equipped with any additional equipment (including the gas puri- fication system, the food, and raw material pretreatment system, the gas or liquid fuel burner, etc.). 3. Technology features of the mobile essential oil distillation system Fig. 5. Mobile Facility for Essential Oil Production (Woodex It is possible to deliver not only roundwood (logs, assort- 2020). ments) to the timber terminal, but also the crown part (with minimum stacked-volume ratio) for processing in After loading the tanks (water, WG, fuel), a cycle lasts mobile extractive plants with obtaining quite demanded about 3 hours, of which the evaporation process itself biologically active substances (Yousuf et al. 2021). For is about 2 hours, with the cooling capacity of 40 kg of instance, in recent years the demand for essential oils steam per hour. from Pinus sylvestris and Picea abies has increased The duration of the cycle depends on many param- (Neis et al. 2019). However, traditionally, this product eters, such as the state of the source material, physical is obtained only in complex woody greenstuff (WG) condition of the operator(s), and others. Usually, one processing facilities in a unique process stream with the operator is enough, but considering the safety require- production of extractive substances. Pine and spruce ments and the possibility to significantly reduce the time plants contain a small number of essential oils, and the of preparatory and auxiliary works, two operators are production of essential oils only under steady-state con- required (operator/operator or operator/driver). 55 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 A manual woody greenstuff chopper is used to dis- material can be classified. This information then goes to other workshops and system elements for further prerse (prepare) the material. A manual woodchopper processing operations. The limitation of this system is or machete can be employed as well. The needles are not that it provides data about the external structure of the fully separated, they are used at the same time as small logs, and the internal structure analysis would require twigs. Waste is left on site. The dismantling or reassem- computed tomography. bly of the equipment takes about half an hour. In timber production, computed tomography became When the plant reaches the site, the operating area widely used since its first application in internal defect is determined and the equipment is deployed. Then, the detection in the early 90s. X–rays penetrate a log without water is poured and boiled, WG is being prepared (dis- damaging it, permitting the internal structure analysis persed) and loaded, the vapor is being passed through a prior to sawing. Timber mapping allows the production distiller, the vapor is being passed through the second of high quality timber products with less waste, as well distiller, the first is released and loaded again, and so on. as the rational use of raw materials (Rummukainen et Produced essential oils are purchased by the manufactur- al. 2021). The wood processing enterprises currently ers of medications for the disinfection of living spaces and use industrial stationary scanners, which are part of an the prevention of colds. automated log processing system. Data from the scanner also serve as an input for AI- aided sawing simulations. Using artificial intelligence to 4. Innovative technologies of wood log simulate sawing and cutting operations makes it possible processing to evaluate different sawing/cutting options and chose the best one according to the accepted timber quality One of the innovative technologies used in timber process- standards (Olofsson et al. 2019). Using a computer- ing that can also be applied in mobile timber terminals is a based model, one may implement an integrated approach portable laser scanning technology (Pyörälä et al. 2018). to establishing the value of the end product up to the saw- Through laser scanning and real-time data processing, ing stage. For this, a software needs to be developed to such systems accurately and safely examine the volume link the properties of logs and final products. and biometric characteristics of logs. The market offers The BoardMasterNOVA scanner (FinScan 2021) ground and air-based laser scanners that allow the col- enables an automated sorting of logs and can provide lection of data before logging using unmanned aerial complete analysis of both green and dry boards, per- vehicles and mobile robots (Székely et al. 2017). formed in different directions. BoardMasterNOVA is Woodtech.Logmeter’s solution to obtain general capable of accurate wood defect detection and product information about logs (WoodTech 2021) is an excellent classification. The Logeye 300 Stereo True Shape Log fit for timber terminals. The company uses a modern log Scanner from Microtec (2021) is based on a stereoscopic scanning technology (Logmeter) that allows examining imaging technology that allows you to scan a log in real the logs without unloading the truck (Fig. 6). This scan- time while creating 3D images. With the help of innova- ning system can be installed at the entrance/exit to the tive technology, Logeye 300 Stereo is able to scan logs terminal. of various sizes and diameters, as well as optimize the sawing process. After sawing, timber boards are tested on modern sys- tems that use multi-point scanners to distinguish good wood from defective wood. One example of such scan- ners is Gocator 250 (LMI Technologies 2021), a scanning system produced by LMI Technologies (Fig. 7). As shown in Fig. 7, Gocator 205 is equipped with a vision module that uses color to capture external wood defects, such as twigs, cracks and rot. Besides scanners that collect data, one may need a powerful software to process data. Lucidyne produces scanners with integrated GradeScan's Perceptive Sight Intelligent Grading software (Lycidyne 2021), which automates the wood processing operations and identi- e fi s softwood from hardwood. USNR (2021) has applied Fig. 6. An automated scanning system (Logmeter) to esti- a Deep Learning technology to image processing systems mate biometric characteristics of logs (WoodTech 2021). to achieve faster and more accurate grading. Another innovative technology for wood scanning is the Autolog Information from the Logmeter is transmitted imme- GEN3 log optimizer (Autolog 2021), designed to opti- mize primary log breakdowns and reproduce sowing diately to the operator, who, based on the volume and curves with log rotations. biometric estimates, determines a class to which the raw 56 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 of biofuels supply through road terminals and obtained similar results. Thus, the inclusion of terminals has been shown to reduce the total operating costs of biofuels sup- ply by 18.3% from 7.1 to 5.8 million euros. Similar results were obtained in the work of Kühmaier et al. (2016), com- paring the maintenance costs of the terminals by region. It has been shown that the reduction of the terminal zone has economic benefits when the annual turnover is less than 50000 m of bulk materials. Labokas et al. (2017) found that freshly harvested pine foliage contained a minimum of 17 kg of conifer- ous essential oil per hectare of mature pinewood, but the total yield of essential oils decreased after transportation to the processing plant. Installing a mobile processing station at the felling site or at timber terminals can sig- nificantly reduce the amount of waste from essential oil Fig. 7. Gocator 250 scanner to identify wood defects in timber boards (LMI Technologies 2021). production and enhance the product quality, and the use of biomass gasification technology will facilitate waste recycling (Kislukhina & Rybakova 2018). All of the above results indicate that the rational 5. Discussion layout of the terminals and the use of additional waste The use of proposed developments and upgrading tech- treatment technologies can signic fi antly save the costs of niques might help optimize the energy efficiency of the shipment and purchase of raw materials. Moreover, this temporary timber terminals and reduce the costs of can increase the profit of enterprises, reduce waste, and transportation and primary processing of raw materi- mitigate the negative impact on the environment. als. Besides, the production of fuel pellets, essential oil, and gas synthesis from low-quality wood at the terminals saves on transportation and waste disposal, increasing 6. Conclusions product quality, since the process occurs immediately after wood treatment. When designing a timber termi- Proposed technological solutions for the upgrade and nal, it is also possible to adapt the location of production optimization of forest material treatment at temporary lines to the leased area. It will reduce energy costs and timber terminals significantly reduce the costs of trans- increase the rapid transportation of finished products portation, shipment, and processing of low-quality wood without impairing the quality. and residues. Also, they provide autonomy and mobil- Many studies have focused on the rationality of ity of the terminals from the central power supply. It using terminals in the production of fuel pellets in dif- is shown that the use of a mobile pellet system allows ferent European countries. Berg and Athanassiadis obtaining biofuel from waste wood cleaning with a spe- (2020) based on the Combopt optimization method, cific carrying capacity of 1000 kg per m and power con- modeled terminal options to minimize the costs of col- sumption of 250.0 kW. The installation of a mobile plant lecting, transporting, and logging waste in Sweden. Six for essential oils production on the terminals was found to options were modeled to meet the anticipated demand have an annual economic effect. The overview of modern from processing plants, with an estimated cost of SEK scanning technologies revealed that portable laser scan- 3.1 to 35.4 million, which was 0.5 to 6.1% of the total ners provide complete information about the biometric procurement cost. These results are consistent with the characteristics of the logs, while the use of computed n fi dings of this study, indicating that the use of temporary tomography and deep learning technologies permits the terminals for the treatment of forestry waste is efficient real-time assessment and classification of internal wood and cost-effective. defects. The wood processing simulations help to choose Similar results were achieved in the work of Gautam the best sawing patterns and thus improve the quality of et al. (2017), where the benefits of including a terminal wood and minimize waste. 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Analysis of modern wood processing techniques in timber terminals

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de Gruyter
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© 2022 Oľga Kunickaya et al., published by Sciendo
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10.2478/forj-2021-0017
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Abstract

The transportation of forestry products is performed over long distances and is quite expensive, which limits the development of biofuel plants in Russia and around the world. The use of timber terminals contributes to transporta- tion cost reduction and mitigates negative environmental impacts. This work aims to analyze various technological solutions for optimization of forestry products processing at temporary terminals and cost reduction of transporta- tion, shipping, and wood treatment. The work presents a discussion on the technological and economic possibilities of the mobile pellet plant, the mobile essential oil production plant, and an enhanced autonomous electric generator system. It is shown that the use of mobile plants for obtaining pellets and essential oils allows processing wood residues at the terminal, which reduces the cost of transportation and shipment of raw materials and improves the quality of the finished products. The current study also examines some of the modern scanning technologies used to detect log defects and obtain complete biometric information in real time while assessing the productivity of wood processing operations. The results of the study can be used to develop efficient movable timber terminals. Key words: energy wood; equipment; fuel; storage location; supply chain Editor: Bohdan Konôpka ment of quality roundwood in the developed commercial 1. Introduction forests and the associated continued growth of the log- With the aim of reducing the impact of human activities ging transportation arm, which has already exceeded on climate change and environmental ecology in the glo- 300 km in Siberia and the Far East (Lobovikov & Pry- bal community, different actions to reduce the extraction adilina 2020; Likhouzova & Demianova 2021). Mature of fossil energy resources and the transition to renew- and over-mature forests in proximity to the main wood able energy sources in the production and transmission processing centers, often remain only in less developed processes have been undertaken (Dogaru 2020; Halkos swampy or heavily rugged areas (Mokhirev & Goryaeva & Gkampoura 2020; Morita et al. 2002). The success of 2017). The growth of the harvested timber transportation such a transition depends on optimizing the supply of arm along with an increase in the specific fuel consump- renewable raw materials, developing competitive pro- tion for the transportation of a depleted cubic meter of duction systems, and long-term regulation to compete wood and the specific depreciation of wood trucks leads against fossil fuel products (Giuliano et al. 2016). to a significant increase in the cost of harvested timber. Currently, there is an excess of forest biomass in It is associated with the need to finance the building and Northern European and Russian countries, which maintenance of an extensive network of forestry roads. includes discarded wood, forest residues, branchwood, and stumps (Athanassiadis & Nordfjell 2017). In the Rus- At the same time, the prospects for offsetting the costs sian forestry sector, there has been a gradual impoverish- of developing a network of forest roads for forest users *Corresponding author. Oľga Kunickaya, e-mail: olkunickaya67@rambler.ru O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 are still not developed (Kozlov et al. 2019). Despite the (2021) held a meeting of the subcommission on customs- comparatively low payment rate for forest resources in tariff, non-tariff regulation, and protective measures in Russia, timber harvested from natural forests is becom- foreign trade, at which it was decided to introduce a tem- ing less and less competitive in terms of production costs, porary two-year restriction on the export of veneer blocks. which is illustrated in Fig. 1. The study of the situation with raw materials at Russian veneer enterprises showed a negative trend in the supply of veneer logs to processing industries and an increase in exports of these raw materials to China. For a while, this has helped mitigate the shortage of raw materials for domestic veneer enterprises, but it is only a reprieve. This is largely due to the incorrect policy in the field of reforestation and the absence of a policy on the cultiva- tion of deciduous plantations of seed origin (Kuzminyh et al. 2020; Uvsh et al. 2020). The solution for this problem might be the development of the target cultivation (plant- ing) of wood, as is accepted in most countries of the world (Bulat et al. 2017; Kemppinen et al. 2020). Currently, the most requested round woods in Rus- sia are conifer logs (diameter, 14–38 cm), balance logs (diameter, 6–24 cm), and plywood logs (diameter, 18 cm onwards). There is also a problem of low-quality wood Fig. 1. Indufor analysis of sawn logs costs (InduforGroup accumulation on the rental bases of forest companies that 2021). require extensive development and implementation of technological processes for effective wood processing. Moreover, the ongoing removal of forest harvest- It is needed, at least, to ensure that the added value of ing sites for mature and overmature stands away from products derived from such timber covers the costs of the personnel residences of forest companies (sites) its harvesting (Loučanová et al. 2017). To address this leads to increased use of shift logging methods. In turn, issue in Russia, government strategies for collecting and it is associated with establishing shift work camps and some processing non-wood (food) forest products have been infrastructure of their service, which also increases the cost of adopted since 2009. However, this process calls for very harvested wood (Tambi et al. 2017). The cost structure for specific machine and equipment systems. Besides, har- roundwood with its own leasing base is shown in Fig. 2. vested forest food products cannot be transported over The cost of wood harvesting can be reduced by opti- long distances. Such wood must be processed in the near- mal planning of transportation from the logging site est places to the logging sites and in the shortest possible (Mokhirev et al. 2019; Rudov et al. 2019). time in order to avoid significant quality loss (Lovrić et The difc fi ulties of forestry enterprises and the exhaus - al. 2020; Stryamets et al. 2020). tion of available quality resources of mature forests lead In the development of forest areas away from wood- to a shortage of wood raw materials for domestic wood processing sites, there is increasing use of the temporary processing enterprises. For example, in March 2018, the timber terminal principle. Timber terminals are tradition- Ministry of Industry and Trade of the Russian Federation ally used as storage and transshipment points for round- Fig. 2. Cost structure of roundwood in case of the own leasing base, RUB per m (Tambi et al. 2017). 52 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 wood within forest industry supply chains (Korpinen et efficient compared to direct raw material supply chains. al. 2018; Berg & Athanassiadis 2020). Currently, timber Furthermore, dust emissions and explosions, destruction terminals are primarily in place to facilitate the distribu- during storage, self-heating, and ignition are important tion of roundwood supply and processing. The principle criteria in the design of a terminal for wood pellet plants. of timber terminals placement in the leasing base under Also, it may signic fi antly affect related logistics. However, development is illustrated in Fig. 3. based on a review of existing technological solutions in The principle of temporary timber terminals based various European countries (Dafnomilis et al. 2018), on mobile wood processing equipment is the primary there is a small volume of wood pellet plants, but constant processing of harvested wood with the further produc- equipment modernization and the rebuilding of termi- tion of timber, the stacked-volume ratio of which is close nals contribute to increased volume of products received. Fig. 3. Principle of a temporary timber terminal establishment in the developed leasing base (Marques et al. 2012). to 100%. In the future, the wood obtained using mobile In addition to that, producing essential oils from timber sawmills can be treated with antiseptic, if necessary (for by-products, such as branches and shoots of spruce and example, during the warm season) and then exported to pine, at timber terminals can increase the output of essen- specialized sawmills for the final processing into high- tial oils without losing their valuable properties. Labokas quality sawn wood (Gedjo et al. 2020). Furthermore, et al. (2017) discovered that storage of pine leaves at cold wooden terminals may also be used to produce pellets temperatures has an adverse effect on the overall yield of and other products. For example, in many developed pine essential oils compared to when the leaves are fresh. countries, such as Japan and South Korea, there is a Therefore, developing a mobile system for producing trend towards decreasing the consumption of fossil essential oils is an urgent task. Consequently, it is impor- fuels and switching to renewable energy sources (Jafari tant to consider the operating and energy costs in plan- et al. 2020; Junginger et al. 2020). Japan has adopted ning and designing the terminals. The current state of a strategy that aims to increase pellet fuel consumption terminals and available modern technological solutions to 20% by 2030; as a result, the demand for this type of are of great relevance when it comes to process optimiza- product is constantly increasing (Pambudi et al. 2017). tion, and mobility/maintenance cost reduction. Timber The largest pellet supplier to these countries is Canada, terminals as temporary yards usually have no centralized which accounted for approximately 63% of pellet imports electricity generation. The use of internal combustion in 2015 (Ahl et al. 2018). In the European Union, there is engines as power stations considerably increases the cost a similar trend of utilizing wood pellets as fuel in thermal of wood processing, given that the cost of fuel is rather power plants and for building heating purposes (Daf- important and that the efficiency factor of internal com- nomilis et al. 2017). Given these trends, the demand for bustion engines is much lower than that of electric motors wood pellets will only grow bigger, which necessitates (Bhandari et al. 2015; Savelev et al. 2019). Besides, the the need to improve production processes and logistics transition from traditional to renewable energy sources in Russia to enable import to Europe and Asia. Virkkunen enables efficient use of technology with full processing et al. (2016) explored the cost-effectiveness of using ter- cycle of logging and wood industry waste. minals for biomass storage, processing, and fuel supply Modern energy can be characterized by tendencies to under any conditions in Finland. The study results on the diversify sources, increase autonomy, reliability, safety, costs for maintaining satellite terminals and developing environmental friendliness, and use of new materials forest fuel logistics showed that terminals are not more (Aruova et al. 2020). Alternative and renewable energy 53 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 sources include wind and hydroelectric systems, biogas 2. Technological and energy features plants, solar collectors, photovoltaic inverters, and heat of the mobile pellet line at timber terminals pumps for the extraction of low-potential heat from the For sawing up to 50 m of wood per shift, it is sufc fi ient to ground, water, and air (Vo et al. 2020). Another alter- equip the sawing terminal with a single-passage sawmill native source of electricity at mobile timber terminals with an energy consumption of about 37 kW. When saw- can be a gas generator (Tsyvenkova et al. 2020), which ing 80–210 m per shift, it is optimal to equip the timber uses waste (tree bark, branches, and stumps) from wood terminal with a mobile crossover line with feed speeds processing operations as fuel. The use of modern tech- up to 30 m per min. The electricity consumption of this nologies in material engineering (Pomiguev et al. 2018) line is approximately 340 kW. For 300 m per shift saw- makes it possible to increase gas generator’s efficiency, ing, the timber terminal is ideally to be equipped with a stabilize electricity generation from biofuels, and reduce mobile feeder with a speed of up to 50 m per min. The the size of the terminal for better transportation (Zagrut- power consumption of this line is approximately 750 kW dinov et al. 2017). In addition, timber by-products may be (Tambi et al. 2019). a basis for the production of many other products (e.g., The use of mobile granulation devices allows obtain- essential oils, pellets, and shavings), some of which can ing not only the thermal (electrical) energy but also the n fi d use in pharmaceutical, chemical and light industries. finished product in the form of pressed biofuel from the Main objective of this study is to analyze various mod- primary wood treatment at the terminal (Ghaffariyan et ern technologies and ways to optimize the structure of al. 2017). timber terminals. To this end, the work provides a review The dimensions of the mobile pellet line correspond of modern techniques and systems for processing logs to the dimensions of a 40- foot container (drying mod- and forestry materials to obtain high-quality products ule), an extended 20-foot container (pelletizingm odule), and reduce the cost of transporting raw wood and other and a 20-foot container (wood preparation module). The products through Russia. The results of the analysis of equipment of the modules is located on specially created waste-free production techniques and advices made power frames with landings for its installation on stand- based on them can be useful in designing timber termi- ard container trucks and the necessary slinging elements nals for better process optimization and to increase the for loading and unloading operations (Fig. 4). quality and range of timber products. To install the line on the top warehouse, a level horizon- tal platform with a specic fi load capacity of 1000 kg per m is required. The actual demand of the line is 250.0 kW with an installed power factor of 0.7. The use factor may vary depending on the feedstock properties (species Fig. 4. Mobile pellet line: a) in transport position; b) in working position (Tambi et al. 2019). 54 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 composition, incoming moisture, etc.). There are three ditions is not economically viable. The main expense is employees on duty handling the shift. the WG transportation to the processing site with an The time required to prepare the line for operation extremely low stacked-volume ratio in the truck. shall not exceed 20 hours. It consists of unloading the line Technological processes of logging operations with and installing the line modules, joining them together, the use of feller-buncher machines, tractors with bundle installing cyclones and gas ducts, which are in the trans- grapple, processors at the top storage, gasoline-powered port and working position, and connecting the line to the saws, and systems for skidding trees with crowns and power supply grids. The height of the line in the working delimbers at the top storage allow concentrating biomass position is increased by installing projecting elements of tree crowns, including WG, by the roadside. The use of (cyclones and gas lines) up to 5.6 m. The raw materials harvesters and forwarders allows collecting concentrated for production, the non-commercial wood up to 370 mm heaps of logging residues with special pickers, bringing in diameter, first arrives on the hydraulic trestle. Then, it them to the roadside. From there, a small mobile unit for goes to the wood splitter piece by piece with subsequent the distillation of essential oil will be located at the place cross-cutting of the tree-length log into pieces up to 0.5 of WG concentration near the road. m and their splitting. Afterward, the raw material is Wood from twigs and branches is intended to use as delivered by the conveyor belt on the chipper with further fuel, and the air from a battery-powered fan is used to delivery of the received wood chip to the hopper-feeder. cool down the isotropic mixture of water vapor and oil. Then, the disk separator sorts out the bark and other cas- The material is expected to be mounted on a car trailer. ual subjects (including stones), which should not go into Mobile facility for the production of essential oils further processing. The sorted chips go into the hammer under logging site conditions, Fig. 5, consists of steam grinder. Then, using a conveyor, the finished wood pulp generator, two distillation devices (reservoirs for WG), enters the heat generator and the rotating drying drum condenser, separating flask, and box for the equipment through a raw material dispenser. The dried wood gets used. The unit operates with a closed water cycle, sepa- into the pneumatic discharge cyclone and the hammer rating flask is used for steam production, which reduces grinder. Exhaust gases are discharged from the cyclone energy costs and improves the efficiency of essential through a flue gas vacuum through a stack into the oils. Equipment technology parameters are designed to atmosphere. After a hammer grinder, the groundwood operate at air temperatures between –10 °C and +20 °C. enters a pellet press by a cyclone. The finished granu - Technological characteristics of the unit are described lates are transported by a conveyor belt to the chiller and in Woodex (2020). then to the vibrating screen. Afterward, pellets ready to be sieved using a scraper conveyor enter for packaging. Unsorted pellets and dust after the chiller and vibrating screen are reoriented for granulation using the cyclones and pneumatic conveying system. The line is controlled using only one control panel. As an option, on request, the line can be equipped with any additional equipment (including the gas puri- fication system, the food, and raw material pretreatment system, the gas or liquid fuel burner, etc.). 3. Technology features of the mobile essential oil distillation system Fig. 5. Mobile Facility for Essential Oil Production (Woodex It is possible to deliver not only roundwood (logs, assort- 2020). ments) to the timber terminal, but also the crown part (with minimum stacked-volume ratio) for processing in After loading the tanks (water, WG, fuel), a cycle lasts mobile extractive plants with obtaining quite demanded about 3 hours, of which the evaporation process itself biologically active substances (Yousuf et al. 2021). For is about 2 hours, with the cooling capacity of 40 kg of instance, in recent years the demand for essential oils steam per hour. from Pinus sylvestris and Picea abies has increased The duration of the cycle depends on many param- (Neis et al. 2019). However, traditionally, this product eters, such as the state of the source material, physical is obtained only in complex woody greenstuff (WG) condition of the operator(s), and others. Usually, one processing facilities in a unique process stream with the operator is enough, but considering the safety require- production of extractive substances. Pine and spruce ments and the possibility to significantly reduce the time plants contain a small number of essential oils, and the of preparatory and auxiliary works, two operators are production of essential oils only under steady-state con- required (operator/operator or operator/driver). 55 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 A manual woody greenstuff chopper is used to dis- material can be classified. This information then goes to other workshops and system elements for further prerse (prepare) the material. A manual woodchopper processing operations. The limitation of this system is or machete can be employed as well. The needles are not that it provides data about the external structure of the fully separated, they are used at the same time as small logs, and the internal structure analysis would require twigs. Waste is left on site. The dismantling or reassem- computed tomography. bly of the equipment takes about half an hour. In timber production, computed tomography became When the plant reaches the site, the operating area widely used since its first application in internal defect is determined and the equipment is deployed. Then, the detection in the early 90s. X–rays penetrate a log without water is poured and boiled, WG is being prepared (dis- damaging it, permitting the internal structure analysis persed) and loaded, the vapor is being passed through a prior to sawing. Timber mapping allows the production distiller, the vapor is being passed through the second of high quality timber products with less waste, as well distiller, the first is released and loaded again, and so on. as the rational use of raw materials (Rummukainen et Produced essential oils are purchased by the manufactur- al. 2021). The wood processing enterprises currently ers of medications for the disinfection of living spaces and use industrial stationary scanners, which are part of an the prevention of colds. automated log processing system. Data from the scanner also serve as an input for AI- aided sawing simulations. Using artificial intelligence to 4. Innovative technologies of wood log simulate sawing and cutting operations makes it possible processing to evaluate different sawing/cutting options and chose the best one according to the accepted timber quality One of the innovative technologies used in timber process- standards (Olofsson et al. 2019). Using a computer- ing that can also be applied in mobile timber terminals is a based model, one may implement an integrated approach portable laser scanning technology (Pyörälä et al. 2018). to establishing the value of the end product up to the saw- Through laser scanning and real-time data processing, ing stage. For this, a software needs to be developed to such systems accurately and safely examine the volume link the properties of logs and final products. and biometric characteristics of logs. The market offers The BoardMasterNOVA scanner (FinScan 2021) ground and air-based laser scanners that allow the col- enables an automated sorting of logs and can provide lection of data before logging using unmanned aerial complete analysis of both green and dry boards, per- vehicles and mobile robots (Székely et al. 2017). formed in different directions. BoardMasterNOVA is Woodtech.Logmeter’s solution to obtain general capable of accurate wood defect detection and product information about logs (WoodTech 2021) is an excellent classification. The Logeye 300 Stereo True Shape Log fit for timber terminals. The company uses a modern log Scanner from Microtec (2021) is based on a stereoscopic scanning technology (Logmeter) that allows examining imaging technology that allows you to scan a log in real the logs without unloading the truck (Fig. 6). This scan- time while creating 3D images. With the help of innova- ning system can be installed at the entrance/exit to the tive technology, Logeye 300 Stereo is able to scan logs terminal. of various sizes and diameters, as well as optimize the sawing process. After sawing, timber boards are tested on modern sys- tems that use multi-point scanners to distinguish good wood from defective wood. One example of such scan- ners is Gocator 250 (LMI Technologies 2021), a scanning system produced by LMI Technologies (Fig. 7). As shown in Fig. 7, Gocator 205 is equipped with a vision module that uses color to capture external wood defects, such as twigs, cracks and rot. Besides scanners that collect data, one may need a powerful software to process data. Lucidyne produces scanners with integrated GradeScan's Perceptive Sight Intelligent Grading software (Lycidyne 2021), which automates the wood processing operations and identi- e fi s softwood from hardwood. USNR (2021) has applied Fig. 6. An automated scanning system (Logmeter) to esti- a Deep Learning technology to image processing systems mate biometric characteristics of logs (WoodTech 2021). to achieve faster and more accurate grading. Another innovative technology for wood scanning is the Autolog Information from the Logmeter is transmitted imme- GEN3 log optimizer (Autolog 2021), designed to opti- mize primary log breakdowns and reproduce sowing diately to the operator, who, based on the volume and curves with log rotations. biometric estimates, determines a class to which the raw 56 O. Kunickaya et al. / Cent. Eur. For. J. 68 (2022) 51–59 of biofuels supply through road terminals and obtained similar results. Thus, the inclusion of terminals has been shown to reduce the total operating costs of biofuels sup- ply by 18.3% from 7.1 to 5.8 million euros. Similar results were obtained in the work of Kühmaier et al. (2016), com- paring the maintenance costs of the terminals by region. It has been shown that the reduction of the terminal zone has economic benefits when the annual turnover is less than 50000 m of bulk materials. Labokas et al. (2017) found that freshly harvested pine foliage contained a minimum of 17 kg of conifer- ous essential oil per hectare of mature pinewood, but the total yield of essential oils decreased after transportation to the processing plant. Installing a mobile processing station at the felling site or at timber terminals can sig- nificantly reduce the amount of waste from essential oil Fig. 7. Gocator 250 scanner to identify wood defects in timber boards (LMI Technologies 2021). production and enhance the product quality, and the use of biomass gasification technology will facilitate waste recycling (Kislukhina & Rybakova 2018). All of the above results indicate that the rational 5. Discussion layout of the terminals and the use of additional waste The use of proposed developments and upgrading tech- treatment technologies can signic fi antly save the costs of niques might help optimize the energy efficiency of the shipment and purchase of raw materials. Moreover, this temporary timber terminals and reduce the costs of can increase the profit of enterprises, reduce waste, and transportation and primary processing of raw materi- mitigate the negative impact on the environment. als. Besides, the production of fuel pellets, essential oil, and gas synthesis from low-quality wood at the terminals saves on transportation and waste disposal, increasing 6. Conclusions product quality, since the process occurs immediately after wood treatment. When designing a timber termi- Proposed technological solutions for the upgrade and nal, it is also possible to adapt the location of production optimization of forest material treatment at temporary lines to the leased area. It will reduce energy costs and timber terminals significantly reduce the costs of trans- increase the rapid transportation of finished products portation, shipment, and processing of low-quality wood without impairing the quality. and residues. Also, they provide autonomy and mobil- Many studies have focused on the rationality of ity of the terminals from the central power supply. It using terminals in the production of fuel pellets in dif- is shown that the use of a mobile pellet system allows ferent European countries. Berg and Athanassiadis obtaining biofuel from waste wood cleaning with a spe- (2020) based on the Combopt optimization method, cific carrying capacity of 1000 kg per m and power con- modeled terminal options to minimize the costs of col- sumption of 250.0 kW. The installation of a mobile plant lecting, transporting, and logging waste in Sweden. Six for essential oils production on the terminals was found to options were modeled to meet the anticipated demand have an annual economic effect. The overview of modern from processing plants, with an estimated cost of SEK scanning technologies revealed that portable laser scan- 3.1 to 35.4 million, which was 0.5 to 6.1% of the total ners provide complete information about the biometric procurement cost. These results are consistent with the characteristics of the logs, while the use of computed n fi dings of this study, indicating that the use of temporary tomography and deep learning technologies permits the terminals for the treatment of forestry waste is efficient real-time assessment and classification of internal wood and cost-effective. defects. The wood processing simulations help to choose Similar results were achieved in the work of Gautam the best sawing patterns and thus improve the quality of et al. (2017), where the benefits of including a terminal wood and minimize waste. 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Journal

Forestry Journal – de Gruyter

Published: Mar 1, 2022

Keywords: energy wood; equipment; fuel; storage location; supply chain

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