MWh-RoadMap - Sigmaticmetsate1.asiakkaat.sigmatic.fi/wp-content/uploads/... · MWh-RoadMap Sustainable Bioenergy Solutions for Tomorrow (BEST) program Timo Melkas, Metsäteho Oy Jouni

MWh-RoadMap

Sustainable Bioenergy Solutions for Tomorrow (BEST) program

Timo Melkas, Metsäteho Oy Jouni Tornberg, Measurepolis Development Oy

www.metsateho.fi

Metsätehon tuloskalvosarja 4b/2015 Melkas & Tornberg16 February 2015

Objective• The objective of MWh–roadmap is to describe and to create

procedures to define the heat value and energy content at the different stages in the supply chain from the harvesting site to the plant.– Present supply chains for small size stem wood (karsittu ja karsimaton ranka),

logging residues and stumps and their proportions are presented.

– Present measuring methods and measurement needs at the different stages in the supply chain are presented.

– Potential measuring methods to the future terminal concept and supply chain are presented (needs to develop measuring and estimation methods of moisture content, incl. soft sensor methods).

• Developing methods to monitoring quality of the raw material during the supply chain.

• Developing calculation of MWh during supply chain and real time controlling of heat value.

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Measurement methods of energy wood – today and in the future

Measurements at the harvesting site

Measuring or estimation of moisture content (quality control of raw material) and heat value throughout the entire supplychain.

-More accurate measuring at the roadside (measured moisture content for every stand) and quality feedback to the supplier-Forecasting models for drying based on the measured moisture content and weather information → the timing of delivery to the plant

Logging residues

Small-sized stem wood, whole tree

Harvester measurementV, m3

Stumps

Weighing (loader scales)m, kg → V, m3

Measuring in forest chipsVirto, m3 → Vk, m3

Estimation method, V, m3

based on stem volume of removed trees

at the harvesting site

Estimation method V, m3

based on the size of the cutting area

Pile measurementVkehys, m3 → V, m3

Weighingm, kg → V, m3


Online measurement methodsfor chips and moisture

Virto, m3 → Vk, m3

Energy content




Measuring in forest chipVirto, m3 → Vk, m3



Measuring of crushedmaterial



Online measurement methods for chips and moisture


Energy content


Online measurement methods for chips and moisture


Energy content


Measuring of moisturecontent with a handhelddevice or estimation of moisture content with

forecasting models Online/Offline measuringof moisture content, Soft

sensor methods

0.1 TWh, 50 000 m3

Storage at theroadside, loading

terminal

0.7 TWh, 0.35 mill. m3

Bioterminal1.0 TWh, 0.5 mill. m3

Power plant

COLOR COMMENTARY Black - the current methods

Grey - methods that will be used less often in the future

Red - the new developed methods Measuring of foreignmatter (purity of material)

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Review Guide to the MWh-roadmap

• MWh-roadmap consists of three levels – Energy wood supply chains and their proportions – Supply chains of small wood, logging residues, stumps– Present measurements methods and measurement needs in the supply chain

• In the MWh–roadmap you can go forward by clicking the different raw materials (e.g. small trees, logging residues, stumps, etc.), and view the alternative procurement logistics chains of different materials.

• By clicking with the mouse the desired chain (A, B, C, etc.) you can examine in more detail measurements performed in the supply chain as well as measurement needs.

• Potential and measuring methods that are being developed you will find behind the exclamation mark in each supply chain.

• Click the back button to get to the previous level.

• Click on the summary link to get you to the summary.

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Energy wood supply chains 2013

Harvesting site

Plant

Chipping at the roadside

Chipping at the plant

Chipping at the terminal

Small trees Residues Stumps (Decayed round wood)

66 % 76 % 15 % 16 % (2013)

8 % 12 % 40 % 23 %

26 % 12 % 45 % 61 %

2384 GWh 1050 GWh5510 GWh8444 GWh

Total amount of forest chips

16.6/17.4 TWh, 8.3/8.7 milj. m3

(2012/2013)

56.3 %

27.3 %16.4 %

Summary

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Chipping at the roadside:

Chipping at the roadside and transportingto the plant.

Chipping or crushing at the terminal:

Small wood, loggingresidues and stumps aredelivered to the terminal. Transportingafter processing is doneby truck, train or ship. Chipping at the

plant:

Raw material of forest chips is delivered to theplant, where thechipping or crushingis done.

Energy wood supply chains

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Harvesting site

Supply chains of small-sized stem woodand potential measuring points

Roadside Loading terminal Bioterminal Plant


69 %


22 %


9 %

= Chipping = Measuring of moisture content = Weighing by crane scale (forwarder or truck) or material handlers or wheel loaders etc.

= Weighing by weight bridge

= Harvester measurement

A

B

C

= Estimation of moisture content

MWhest MWhMeasured MWhest MWhest MWhMeasured

MWhMeasured MWhMeasuredMWhMeasured

= Measuring result is used as a basis of payments

!

!

!

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Small-sized stem wood– Supply chain A Current measurements and measurement needs

At the - Harvester measurement → V, m3, proportion of tree species

harvesting site - Basic density (kuivatuoretiheys) by tree species → initial moisture, % - Conversion MWh

At the roadside - Weighing with a forwarder's loader scale → m, kg

- Measuring of the moisture content + sampling → moisture at the roadside, % - Conversion MWh

- Prediction of moisture based on drying model or measuring of moisture during chipping → moisture at the roadside, % / moisture during transport, %

- Weighing of forest chips during chipping → m, kg

- Chipping - Conversion MWh

At the plant - Weighing of forest chips with a weight bridge → m, kg

- Measuring of volume by with traditional methods or online –measurements in the conveyor belt or measuring frame volume of forest chips with laser scanning, conversion to solid volume, → V, m3

- Measuring of the moisture using the oven method or by using fast moisture determination methods or online measurements → moisture at the plant, % - Conversion MWh

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Small-sized stem wood – Supply chain A

Development needs / Alternative methodsAt the harvesting site / At the roadside

- Estimation of moisture based on solid volume, tree species and basic density

- Estimation and prediction of moisture based on drying models.

- Measuring of moisture + sampling (dust samples taken by chain saw in the grapple of forwarder or humidity sensors in the storage) → moisture at the roadside, %

- Online –measurements of moisture during chipping → moisture during transport, %

At the plant

- Developing sampling methods more objective (automation and control)

- Developing the fast moisture determination methods and online –measurements (conveyor belt)→ moisture at the plant, %

Feedback System

BACK

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Small-sized stem wood – Supply chain BCurrent measurements and measurement needsAt the - Harvester measurement → V, m3, proportion of tree species




- Weighing with truck’s loader scale → m, kg

- Estimation of moisture content → moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the loading terminal (Transshipment terminal) / at the bioterminal (Satellite-, Feed–in - or Fuel upgrading terminal)

- Weighing with a loader scale or such / Weighing with a weight bridge (whole tree) → m, kg

- Estimation of moisture / Measuring the moisture content of saw dust samples (chain saw) -Conversion MWh

- Chipping

- Measuring of the moisture during chipping or loading → moisture at the terminal, % - Conversion MWh

- Measuring the frame volume of forest chips with laser scanning, conversion to solid volume, → V, m3

- Weighing of forest chips → m, kg



- Measuring of the moisture using the oven method or by using fast moisture determination methods or online-measurements → moisture at the plant, % - Conversion MWh

BACK

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Small-sized stem wood – Supply chain BDevelopment needs / Alternative methods

At the harvesting site / At the roadside



- Measuring of moisture + sampling (dust samples taken by chain saw in the grapple offorwarder or humidity sensors in the storage)

→ moisture at the roadside, %

At the terminal


- Online –measurements of moisture (Measuring during chipping or from saw dust samples collected by using chain saw)

- Measuring the load volume based on laser scanning and using soft sensor –methods → moisture at the terminal, %

At the plant


- Developing the fast moisture determination methods and online –measurements (conveyor belt) → moisture at the plant, %

Feedback System

BACK

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Small-sized stem wood – Supply chain CBACK

Current measurements and measurement needs

At the - Harvester measurement → V, m3, proportion of tree species






→ moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the plant - Weighing with a weight bridge (whole tree) → m, kg

- Measuring the frame volume with laser scanning, conversion to solid volume, → V, m3

- Chipping

- Measuring of the moisture using the oven method or by using fast moisture determination methods or online -measurements

→ moisture at the plant, % - Conversion MWh

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Small-sized stem wood – Supply chain C

Development needs / Alternative methods




- Measuring of moisture + sampling (dust samples taken by chain saw in the grapple of forwarder or humidity sensors in the storage)


At the plant


- Developing the fast moisture determination methods and online –measurements (conveyor belt)

→ moisture at the plant, %

Feedback System

BACK

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Supply chains of logging residues and potential measuring points


75 %


11 %


15 %

D

E

F

BACK

!

!

!

Harvesting site Roadside Loading terminal Bioterminal Plant



= Chipping = Measuring of moisture content = Weighting by crane scale (forwarder or truck) or material handlers or wheel loaders etc.


= Harvester measurement



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Logging residues – supply chain DBACK


At the - Volume estimation based on the removed trees of the stand → V, m3, proportion of tree species harvesting site - Basic density (kuivatuoretiheys) by tree species → initial moisture, %- Conversion MWh



- Prediction of moisture based on drying model or measuring of moisture during chipping → moisture at the roadside, % / moisture during transport, %

- Weighing of forest chips during chipping → m, kg - Conversion MWh

- Chipping



- Measuring of the moisture using the oven method or by using fast moisture determination methods or online measurements


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Logging residues – supply chain D







- Online –measurements of moisture during chipping

→ moisture during transport, %

At the plant




Feedback System

BACK

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Logging residues – supply chain EBACK

Current measurements and measurement needsAt the harvesting - Volume estimation based on the removed trees of the stand → V, m3, propotion of tree species

site - Basic density (kuivatuoretiheys) by tree species → initial moisture, % - Conversion MWh




- Estimation of moisture content → moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the loading terminal (Transshipment terminal) / at the bioterminal (Satellite-, Feed – in - or Fuel upgrading terminal)

- Weighing with a loader scale or such / Weighing with a weight bridge (logging residues) → m, kg

- Estimation of moisture / Measuring the moisture content of saw dust samples (chain saw) -Conversion MWh

- Chipping

- Measuring of the moisture during chipping or loading → moisture at the terminal, % - Conversion MWh

- Measuring the frame volume of forest chips with laser scanning, conversion to solid volume, → V, m3

- Weighing of forest chips → m, kg





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Logging residues – supply chain EDevelopment needs / Alternative methods






At the terminal


- Online –measurements of moisture (Measuring during chipping or from saw dust samples collected by using chain saw)

- Measuring the load volume based on laserscanning and using soft sensor –methods

→ moisture at the terminal, %

At the plant


- Developing the fast moisture determination methods and online –measurements (conveyor belt) → moisture at the plant, %

Feedback System

BACK

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Logging residues – supply chain FBACK


At the harvesting - Volume estimation based on the removed trees of the stand → V, m3, propotion of tree species

site - Basic density (kuivatuoretiheys) by tree species → initial moisture, % - Conversion MWh

At the roadside - Weighing with a fowarder’s loader scale → m, kg




→ moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the plant - Weighing with a weight bridge (logging residues) → m, kg

- Measuring the frame volume with laserscanning, conversion to solid volume, → V, m3

- Chipping

- Online –measurements of volume in the conveyor belt → V, m3



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Logging residues – supply chain F





- Measuring of moisture + sampling (dust samples taken by chain saw or humidity sensors in the storage)


At the plant


- Developing the fast moisture determination methods and online –measurements(conveyor belt)


Feedback System

BACK

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Supply chains of stumps and potentential measuring points

Crushing at the roadside

21 %

Crushing at the terminal

37 %

Crushing at the plant

42 %

= Crushing

= Hakkuukonemittaus

G

H

I

BACK

= Pre-Crushing

!

!

!



Harvesting site Roadside Loading terminal Bioterminal Plant

= Measuring of moisture content = Weighing by crane scale (forwarder or truck) or material handlers or wheel loaders etc.




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Stumps – supply chain GBACKCurrent measurements and measurement needsAt the harvesting - Volume estimation based on the size of the cutting area → V, m3, proportion of tree species

site - Stump splitting during lifting

- Basic density (kuivatuoretiheys) by tree species → initial moisture, % - Conversion MWh


- Estimation or measuring of the moisture content → moisture at the roadside, %

- Conversion MWh

- Prediction of moisture based on drying models or measuring of moisture during crushing → moisture at the roadside, % / moisture during transport, %

- Weighing of stumps during crushing → m, kg - Conversion MWh

- Crushing

At the plant - Weighing of crushed stumps with a weight bridge → m, kg

- Measuring of volume by with traditional methods or online –measurements in the conveyor belt or measuring frame volume of crushed stumps with laser scanning, conversion to solid volume, → V, m3

- Online-measurement of foreign matter (conveyor belt)

- Measuring of the moisture using the oven method or by using fast moisture determination methods or online-measurements


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Stumps – supply chain GDevelopment needs / Alternative methods




- Estimation or measuring of the moisture content (for example measuring the moisture content with a moisture sensor (piikkianturi) or estimating the moisture with humidity sensors in the storage or estimation of moisture content based on solid volume and weight and image analysis)


- Online –measurements of moisture during chipping

→ moisture during transport, %

At the plant


- Online -measurement of foreign matter (conveyor belt)



Feedback System

BACK

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Stumps – supply chain HBACKCurrent measurements and measurement needsAt the - Volume estimation based on the size of the cutting area → V, m3, proportion of tree species


At the roadside - Weighing with a forwarder’s loader scale → m, kg

- Estimation or measuring of the moisture content → moisture at the roadside, % - Conversion MWh


- Estimation and prediction of moisture based on drying models. → moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the loading terminal (Transshipment terminal) / at the bioterminal (Satellite-, Feed–in - or Fuel upgrading terminal)

- Weighing with a loader scale or such / Weighing with a weight bridge (stumps) → m, kg

-Estimation and prediction of moisture based on drying models / Measuring of the moisture content with a moisture sensor (piikkimäisellä anturilla) - Conversion MWh

- Crushing

- Online measuring of the moisture during chipping or loading → moisture at the terminal, % - Conversion MWh

- Measuring the frame volume of crushed stumps with laser scanning, conversion to solid volume, → V, m3

- Weighing of crushed stumps → m, kg

At the plant - Weighing of crushed stumps with a weight bridge → m, kg

- Measuring of volume by with traditional methods or online –measurements in the conveyor belt or measuring frame volume of crushed stumps with laser scanning, conversion to solid volume → V, m3


- Measuring of the moisture using the oven method or by using fast moisture determination methods or online -measurements → moisture at the plant, % - Conversion MWh

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Stumps – supply chain HDevelopment needs / Alternative methodsAt the harvesting site / At the roadside



- Estimation or measuring of the moisture content (measuring the moisture content with a moisture sensor (piikkianturi) or estimating the moisture with humidity sensors in the storage or estimation of moisture content based on solid volume and weight and image analysis) → moisture at the roadside, %

At the terminal

- Estimation and prediction of moisture based on drying models or measuring of moisture from samples during crushing

- Online –measurements of moisture during crushing or loading

- Measuring the load volume (Stumps/Crushed stumps) based on laser scanning and using soft sensor –methods → moisture at the terminal, %

At the plant


- Online-measurement of foreign matter (conveyor belt)

- Developing the fast moisture determination methods and online –measurements (conveyor belt)→ moisture at the plant, %

Feedback System

BACK

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Stumps – supply chain IBACK


At the - Volume estimation based on the size of the cutting area → V, m3, proportion of tree species



- Estimation or measuring of the moisture content → moisture at the roadside, % - Conversion MWh

- Weighing with a truck’s loader scale → m, kg

- Estimation and prediction of moisture based on drying models. → moisture at the roadside, % / moisture during transport, % - Conversion MWh

At the plant - Weighing of stumps with a weight bridge → m, kg

- Measuring frame volume of stumps with laser scanning, conversion to solid volume → V, m3

- Crushing

- Online measuring of crushed stumps volume in the conveyor belt → V, m3


- Measuring of the moisture using the oven method or by using fast moisture determinationmethods or online -measurements → moisture at the plant, % - Conversion MWh

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Stumps – supply chain I

Development needs / Alternative methodsAt the harvesting site / At the roadside



- Estimation or measuring of the moisture content (for example measuring the moisture content with a moisture sensor (piikkianturi) or estimating the moisture with humidity sensors in the storage or estimation of moisture content based on solid volume and weight and image analysis)


At the plant





Feedback System

BACK

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Optimal measuring points

1) At the stand (incl. preliminary information of the stand)

2) At the roadside(in forwarders during unloading)

3) In reception of the terminal(incoming material, feedback to the supplier)

4) In reception of the plant(incoming material, feedback to the supplier)

Estimation of moisture content throughout supply chain.

BACK

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Energy wood supply chain’s measurements in the future

• Initial moisture content after cutting, % - Estimation based on solid volume, proportion of tree species and basic density

• Moisture content at the roadside, % - Estimation based on drying models / Weight with loader scales

• Moisture before transport, % / Moisture at the loading terminal, % - Estimation based on drying models

• Moisture at the bioterminal – Feedback to the supplier of raw material quality– Weighing of every lot (mittauserä)– Estimation of the moisture content or online measuring of moisture content

• By using soft sensor methods to estimate the moisture• By using online–measurements of volume and moisture during chipping

• Moisture at the plant – Feedback to the supplier of raw material quality– Large plant

• Weighing of every lot (mittauserä), online–measuring of moisture content• Developing online–measuring of foreign matter

– Small plant• Weighing of every lot (mittauserä)• Offline–measuring of moisture content, manual sampling / remote monitoring / soft–sensor methods

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Measurements at the Bioterminal• In VTT’s bioterminal concept, terminal functionalities of the terminals are divided

into four categories, each of which have several size classes (1-4):1) Transshipment terminal (Siirtokuormausterminaali)2) Feed – in terminal (Syöttöterminaali)3) Satellite terminal (Satelliittiterminaali) Bioterminal4) Fuel upgrading terminal (Jalostusterminaali)

• When observing potential measurements in terminals in the future, terminal size and how raw materials are supplied to the terminal and shipped from the terminal will be increasingly important. For this reason, potential methods of measurement of different terminals is presented by size class (capacity/year) using the following size distribution:– Small – 0.1 TWh– Medium size – 0.3 TWh– Large – 1.0 ja 0.7 TWh

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Measurements at the Bioterminal • Small terminal- 0.1 TWh/a

– Weighing during material handling by using loader scales and material handlers (no weight bridge)

– Estimation and prediction of moisture based on drying models. – Chipping before delivery – feedback from plant’s reception to the entrepreneur

(measured MWh’s and weight from weight bridge)– For example small transshipment terminal

• Medium size terminal- 0.3 TWh/a– Weighing during material handling by using loader scales and material handlers (no

weight bridge) - Weighing in the conveyor belt during chipping and measuring frame volume of forest

chips in the conveyor belt (applied also for mobile chippers) or alternatively measuring of frame volume of the forest chips in the truck – Moisture content is measured by using soft sensor → moisture estimate

- Stock accounting- For example medium size feed–in terminal

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Measurements at the Bioterminal• Large terminal - 1.0 TWh/a

– Weighing of incoming and outcoming material with a weight bridge– Weighing and measuring frame volume of forest chips in the conveyor belt or

measuring of frame volume of the forest chips in the truck – Moisture content is measured by using soft sensor → moisture estimate

– Online measurement of the moisture content– Online measurement of the foreign matter– Stock management system– For example large fuel upgrading terminal

• Large terminal - 0.7 TWh/a – As above, but does not include e.g. the online detection of foreign matter – No automatic material sorting based on quality– For example large satellite terminal

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Development needs in the supply chain1) Methods for estimation moisture content

- Estimation of moisture content based on volume, tree species and basic density at the stand.- Estimation of moisture content based on soft sensor –methods by using volume and weight

information measured in the terminal.- Developing drying models of energy wood.

2) Methods to measure moisture content (online/offline)- Developing online–measurement methods of moisture content – for instance measuring the

moisture content and weight online during chipping, or at the plant (on the lot or load bases).- Developing moisture measuring and sampling methods of saw dust samples during

forwarding. - Developing online –measurement methods of weight and moisture content of forest chips

during loading (with a loader). - Developing more objective manual sampling methods (automation and control).

3) Measuring and estimation of volume (online)- Developing methods to measure the volume of the load - forest chips, crushed material,

logging residues and stumps. – For instance, measuring the volume based on laser scanning and soft-sensor methods or on image technology etc.– The results can also be used to estimate moisture and energy content.

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Development needs in the supply chain

4) Developing conversion factors- Developing the Eppu–calculator and/or estimation methods of initial moisture content.- Conversion factors for forest chips and crushed material taking into account today’s

chipping and transport facilities in the logistic chain. Also sealing of the material should be taken into account.

- Conversion factors for loader scale measuring especially for long transport purposes (dry material).

5) Other development needs- Developing a feedback system - Feedback to the supplier of raw material quality.

→ improving the supply chain management, the quality of raw material and estimation models (drying models).

- Developing online measurement of foreign matter.

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Utilization of the MWh- roadmap

Based on MWh–roadmap work, the three most important energy wood supply chains will be selected for further studies. Also measurements during these supply chains will be described in more detail. The selected supply chains are: Supply chains of the small-sized stem wood and the logging residues

→ Chipping at the roadside→ Energy wood material going through bioterminals

Supply chain of the stumps→ Crushing and chipping at the terminal or at the plant

A proposal of the measurement methods will be made and their cost will be evaluated Taking in account the new terminal concept and the different size classes of terminals

Design and further research needs of the BEST–program (II two-years period). Implementation of MWh–roadmap, practical testing in the field Moisture and energy content determination during the supply chain - information needs and data

transferring Testing the potential measurement methods in the field

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Remarks

This work was carried out in the Sustainable Bioenergy Solutions for Tomorrow (BEST) research program coordinated by FIBIC Ltd and CLEEN Ltd with funding from the Finnish Funding Agency for Technology and Innovation, Tekes.

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MWh-RoadMap - Sigmaticmetsate1.asiakkaat.sigmatic.fi/wp-content/uploads/... · MWh-RoadMap Sustainable Bioenergy Solutions for Tomorrow (BEST) program Timo Melkas, Metsäteho Oy Jouni