Erin Webb

Development of the Integrated Biomass Supply Analysis and Logistics Model (IBSAL)

The Integrated Biomass Supply & Logistics (IBSAL) model is a dynamic (time dependent) model of operations that involve collection, harvest, storage, preprocessing, and transportation of feedstock for use at a biorefinery. The model uses mathematical equations to represent individual unit operations. These unit operations can be assembled by the user to represent the working rate of equipment and queues to represent storage at facilities. The model calculates itemized costs, energy input, and carbon emissions. It estimates resource requirements and operational characteristics of the entire supply infrastructure. Weather plays an important role in biomass management and thus in IBSAL, dictating the moisture content of biomass and whether or not it can be harvested on a given day. The model calculates net biomass yield based on a soil conservation allowance (for crop residue) and dry matter losses during harvest and storage. This publication outlines the development of the model and provides examples of corn stover harvest and logistics.

Cost Methodology for Biomass Feedstocks: Herbaceous Crops and Agricultural Residues

This report describes a set of procedures and assumptions used to estimate production and logistics costs of bioenergy feedstocks from herbaceous crops and agricultural residues. The engineering-economic analysis discussed here is based on methodologies developed by the American Society of Agricultural and Biological Engineers (ASABE) and the American Agricultural Economics Association (AAEA). An engineering-economic analysis approach was chosen due to lack of historical cost data for bioenergy feedstocks. Instead, costs are calculated using assumptions for equipment performance, input prices, and yield data derived from equipment manufacturers, research literature, and/or standards. Cost estimates account for fixed and variable costs. Several examples of this costing methodology used to estimate feedstock logistics costs are included at the end of this report.

Opportunities and challenges in the design and analysis of biomass supply chains.

The biomass supply chain is one of the most critical elements of large-scale bioenergy production and in many cases a key barrier for procuring initial funding for new developments on specific energy crops. Most productions rely on complex transforming chains linked to feed and food markets. The term ‘supply chain’ covers various aspects from cultivation and harvesting of the biomass, to treatment, transportation, and storage. After energy conversion, the product must be delivered to final consumption, whether it is in the form of electricity, heat, or more tangible products, such as pellets and biofuels. Effective supply chains are of utmost importance for bioenergy production, as biomass tends to possess challenging seasonal production cycles and low mass, energy and bulk densities. Additionally, the demand for final products is often also dispersed, further complicating the supply chain. The goal of this paper is to introduce key components of biomass supply chains, examples of related modeling applications, and if/how they address aspects related to environmental metrics and management. The paper will introduce a concept of integrated supply systems for sustainable biomass trade and the factors influencing the bioenergy supply chain landscape, including models that can be used to investigate the factors. The paper will also cover various aspects of transportation logistics, ranging from alternative modal and multi-modal alternatives to introduction of support tools for transportation analysis. Finally gaps and challenges in supply chain research are identified and used to outline research recommendations for the future direction in this area of study.

Demonstration of the BioBaler harvesting system for collection of small-diameter woody biomass

As part of a project to investigate sustainable forest management practices for producing wood chips on the Oak Ridge Reservation (ORR) for the ORNL steam plant, the BioBaler was tested in various Oak Ridge locations in August of 2011. The purpose of these tests and the subsequent economic analysis was to determine the potential of this novel woody biomass harvesting method for collection of small-diameter, low value woody biomass. Results suggest that opportunities may exist for economical harvest of low-value and liability or negative-cost biomass. (e.g., invasives). This could provide the ORR and area land managers with a tool to produce feedstock while improving forest health, controlling problem vegetation, and generating local employment.

Simulation Modeling for Reliable Biomass Supply Chain Design Under Operational Disruptions

Lignocellulosic biomass derived fuels and chemicals are a promising and sustainable supplement for petroleum-based products. Currently, the lignocellulosic biofuel industry relies on a conventional system where feedstock is harvested, baled, stored locally, and then delivered in a low-density format to the biorefinery. However, the conventional supply chain system causes operational disruptions at the biorefinery mainly due to seasonal availability, handling problems, and quality variability in biomass feedstock. Operational disruptions decrease facility uptime, production efficiencies, and increase maintenance costs. For a low-value high-volume product where margins are very tight, system disruptions are especially problematic. In this work we evaluate an advanced system strategy in which a network of biomass processing centers (depots) are utilized for storing and preprocessing biomass into stable, dense, and uniform material to reduce feedstock supply disruptions, and facility downtime in order to boost economic returns to the bioenergy industry. A database centric discrete event supply chain simulation model was developed, and the impact of operational disruptions on supply chain cost, inventory and production levels, farm metrics and facility metrics were evaluated. Three scenarios were evaluated for a seven-year time-period: 1) bale-delivery scenario with biorefinery uptime varying from 20-85%; 2) pellet-delivery scenario with depot uptime varying from 20-85% and biorefinery uptime at 85%; and 3) pellet-delivery scenario with depot and biorefinery uptime at 85%. In scenarios 1 and 2, tonnage discarded at the field edge could be reduced by increasing uptime at facility, contracting fewer farms at the beginning and subsequently increasing contracts as facility uptime increases, or determining alternative corn stover markets. Harvest cost was the biggest contributor to the average delivered costs and inventory levels were dependent on facility uptimes. We found a cascading effect of failure propagating through the system from depot to biorefinery. Therefore, mitigating risk at a facility level is not enough and conducting a system-level reliability simulation incorporating failure dependencies among subsystems is critical.

Development of a Bulk-Format System to Harvest, Handle, Store, and Deliver High-Tonnage Low-Moisture Switchgrass Feedstock

This project evaluates and compares comprehensive feedstock logistics systems (FLS), where a FLS is defined to comprehensively span from biomass material standing in a field to conveyance of a uniform, industrial-milled product into the throat of a biomass conversion facility (BCF). Elements of the bulk-format FLS evaluated in this project include: field-standing switchgrass dry chopped into bulk format on the farm, hauled (either loose or bulk compacted) to storage, stored with confining overburden in a protective facility, reclaimed and conveyed to bulk-format discharge, bulk compacted into an ejector trailer, and conveyed as bulk flow into the BCF. In this FLS evaluation, bulk storage bins served as a controlled and sensored proxy for large commercial stacks protected from moisture with a membrane cover.