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Future geothermal opportunities in wood processing
Ian Suckling, Peter Hall and Michael Jack Above Ground Geothermal Technologies Workshop July 2014
Wood processing is energy intensive
Processing plant Wood Wood product
Electricity
Water
Process
heat
Chemicals
2011 Energy intensity (PJ per Billion $)
Business weighted average 2.3
Agriculture, forestry & fishing 3.4
Wood, pulp, paper & printing 19.0
Basic metals 16.3
Combustion
Co-location of Geothermal and Forest
Resources
Talk outline
• Forestry sector
• Existing synergies
• Future opportunities
Industrial symbiosis
Residue opportunities
Biofuels
• Conclusions
Current:
High log export volumes
Low productivity wood
processing
Selling into mature markets
Future:
Greater on-shore wood
processing
Innovative solid wood products
New fibre-based products,
biofuels and biochemicals
Exports: $4.5 B → $12 B (2022)
New Zealand wood flows – 2012
Redrawn from: FOA/MPI - NZ Plantation Forest Industry Facts & Figures 2012/2013
Total log input
27.5
Log & chip exports
14.1 51%
On-shore processing
13.3 49%
Poles
0.4 Sawlogs & peelers
8.4
Plywood
1.2
Sawmills
7.3
Plant
residues
3.8
Pulp
3.7 Reconstituted panels
0.9 Energy
61.1 GPJ
Forest residues
n/a
4.5
Volumes in millions m3 roundwood equivalents
Existing synergies
Kawerau site
• Electricity
• Process steam for 4 existing wood processing facilities
largest industrial direct use of geothermal energy in the
world for over 50 years
Wood drying
• 2006 - 20 MW direct heat plant installed at Tenon’s Taupo wood
processing plant
• Replaced natural gas, cutting fuel bill & carbon footprint
• Led to significant efficiency gains
WoodScape analysis of impact of geothermal
P. Hall - Analysis of wood processing opportunities in Kawerau using the WoodScape model (2013)
http://embracechange.co.nz/images/uploads/content-images/ISK_WoodScape_2013_Nov_V3.pdf
Future opportunities Industrial symbiosis
Residue opportunities
Biofuels
Industrial symbiosis
• Industrial symbiosis is an association between two or more
industrial facilities or companies in which the wastes or co-
products of one become the raw materials for another.
• Industrial symbiosis can help companies:
Reduce raw material and waste disposal costs
Earn new revenue from residues and byproducts
Divert waste from landfill and reduce carbon emissions
Open up new business opportunities
• Opportunities will be site-specific
http://www.wrap.org.uk/content/what-industrial-symbiosis
Industrial symbiosis – Kalundborg, Denmark
M Chertow – J. Industrial Ecology 11(1): 1 (2007).
Traditional wood processing
Wood Wood product
Process
steam
Combustion
Residues
Conversion
process
Two inefficiencies:
1. Combustion
2. Reduced temperature
Industrial symbiosis
Wood Wood product
Geothermal
heat
Residues
Conversion
process 1
Conversion
process 2
Biochemical
or biofuel
Residue opportunities
• Bark Wood adhesives
Nutraceuticals
Biofuels
Horticultural applications
• Sawdust Pellets
Biofuels
Biochemicals
Bioplastics
• Lignin Surfactants and binders
Aromatic chemicals
Carbon fibre
WoodScape analysis: separate plants
Wood Sawn
lumber
Residues
Industrial
sawmill
Wood Plywood
Residues
Plywood mill
Biofuel Biofuel plant Wood
residues
350,000 m3/yr
350,000 m3/yr
340,000 m3/yr
182,000 m3/yr
178,000 m3/yr
45 M L/yr
172,000 m3/yr
168,000 m3/yr
Weighted ROCE 15.6%
WoodScape analysis: industrial symbiosis
Wood Sawn
lumber Industrial
sawmill
Wood Plywood Plywood mill
Biofuel Biofuel plant
350,000 m3/yr
350,000
182,000
178,000
45 M Litres
172,000
168,000
+17% gain in weighted ROCE: 15.6% → 18.3%
Geothermal heat
Biofuels - cellulosic ethanol
Feedstock
Sugar solution
Enzymatic hydrolysis
Pretreatment
Ethanol
Fermentation
Enzymes
Residue (process heat & electricity)
New Zealand Lignocellulosic Biofuel Initiative
Chips
Refining
Saccharification
residue
Sugar
syrup
Preheating
Lignin
Pressate
syrup
Heat & power
Enzyme
hydrolysis Attrition
Neutralisation Acid
hydrolysis
Research driven by techno-economic model
Capital Operating
Re
lati
ve P
rod
uct
ion
Co
sts
Operating cost
-
100
200
300
400
500
600
700
Op
era
tin
g C
osts
, $/t
on
ne s
ug
ars
Conclusions
• Strong regional opportunities for synergies between
geothermal resources and wood processing
Additional uses for geothermal
Improve utilisation of wood resource
Industrial symbiosis opportunity
• Opportunities
Reduce conventional wood processing costs
Re-direct wood residues from process heat to saleable
co-products
Enhance viability of new bioproduct opportunities
