Green forest machines
Transkript
Green forest machines
Green forest machines Environmental Guide For the environment Contents 2 For the environment 2 Environment a consideration early on 4 Eco-friendly solutions in John Deere harvesters 6 Eco-friendly technical solutions in John Deere forwarders 8 Slash bundler: Wood energy to counteract climate change 10 Traces of forest machines in the environment – in the atmosphere and in the forest 12 A healthy forest is the best alternative 15 Just like agriculture and silviculture, industry and traffic, forest machines also leave their mark on the environment – in the forest and in the atmosphere. John Deere does its best to minimize the environmental impact of its forest machines at all life cycle stages – without compromising other demands like productivity and operational reliability. The environmental aspects of forest machines can be influenced already in the design phase. Carefully thought out technical solutions, material choices and designs, and instructions and training reduce the environmental impacts caused by the manufacturing, operating and final disposal of forest machines. Ultimately, it is the operator who decides how he will utilize the technical solutions when working in the forest. The usage phase puts the biggest load on nature The life cycle of a forest machine consists of production of the materials needed to make the machine, the assembly at the factory, usage, maintenance and servicing, and final disposal after the usage phase. Studies indicate that emissions are highest during the usage phase of a forest machine. This is primarily due to the fact that the emissions caused by fuel production and fuel consumption are calculated as usage-phase emissions. Naturally, the usage phase also has the biggest impact on the forest environment. Once a forest machine has reached the end of its useful life, the post-use phase of the life cycle begins. At that point, it must be determined which parts and components can be reused, which materials can be recycled, and which must be disposed of in a landfill. John Deere forest machines fully comply with EU directive requirements concerning the recyclability rate of vehicles. Involved in development right from the start The means to mechanize logging were being pursued already a century ago, but the actual development curve of forest machines spans fifty years. John Deere has been involved in the development and production of forest machines right from the start. The company’s roots date back to the 1800s, and the production of forest machines was launched before the mid-1900s. Corporate acquisitions and mergers have resulted in today’s John Deere forest machine manufacturing, which combines European and North American forest machine expertise. 3 Environment a consideration early on Along with forest machine productivity, high operational reliability, and low operating costs, minimizing the impact on the environment is another John Deere attribute that supports its customers’ competitiveness. John Deere takes environmental aspects into consideration early on in the product development phase. Expertise in design reduces the environmental impact of forest machines at all life cycle phases. John Deere also actively participates in studies to map forest machines and their usage. John Deere has invested in minimizing the environmental impact of the machines during the usage phase by integrating many of the technical solutions it has developed. Life cycle of a forest machine The life cycle of a forest machine is divided into five phases: production of materials, manufacturing of the machine, usage of the machine, maintenance and repairs, and the post-use disposal. The VTT Technical Research Center of Finland has studied and assessed the environmental impact of a harvester, forwarder and slash bundler based on the life cycle concept. The percentages of the total environmental impact of the different life cycle phases have been calculated in the study using both the Eco-indicator 95 and Eco-indicator 99H methods. Production of materials The environmental impact of the production and transportation of materials – steel, cast iron and rubber, and the components made from them – is 3.0% of the total environmental impact for a harvester, 5.0% for a forwarder, and 5.6% for a slash bundler. While John Deere has no direct influence on the production processes of raw materials, it can choose raw materials suppliers that take environmental issues into consideration and have certified environmental management systems. Machine manufacturing Assembly of a forest machine accounts for 2-3% of the total environmental impact. John Deere Forestry has invested in environmental management systems for several years and follows a principle of continuous development in its environmental work. In 1999, the Joensuu factory was the first machine manufacturer to be awarded 4 ISO 14001 certification for its environmental management system. In addition to Joensuu, today the certification also covers John Deere’s product development and support functions in Tampere, Finland. Certification requires having an efficient environmental management system in place for planning, implementing, auditing and developing measures that reduce environmental impacts. Usage The emissions caused by the production and consumption of fuel are calculated as usage phase environmental impacts in the life cycle assessment of the forest machine. Accordingly, the environmental impact of harvester usage accounts for 93% of the total impact, forwarder usage 88%, and slash-bundler usage 89%. Emissions are the biggest factor in the environmental impact of the life cycle of a forest machine. John Deere’s product development is constantly pursuing new technical solutions to reduce the consumption of fuel and oil. The driving habits of forest machine operators also have a significant impact on fuel consumption. In addition to emissions that tax the environment, the use of forest machines leave traces in the forest environment. The environmental impact on the forest does not compare to the total environmental impact of fuel production and consumption, but it does have major significance locally. Forest machine operators can reduce the environmental impact on the forest through their own working habits. Maintenance and repairs Usage phase maintenance and repairs, such as replacing tires, changing oil, and other service and wear parts, are also included in the usage phase assessment. Harvester maintenance and repairs account for a 2.0% share of the total environmental impact, forwarders 3.0%, and slash-bundlers 3.3%. Regular, preventive maintenance of forest machines is both eco-efficient and cost-efficient. For instance, it is easier to change hoses preventatively in the workshop than in the forest. This also facilitates the proper handling of hazardous waste through the shop’s waste management system. End-of-life vehicles directive According to the EU directive, the recyclability rate of an end-of-use vehicle must be at least 80% and the recyclability/re-use rate at least 85%. John Deere’s forest machines are well within the requirements of the directive with the recyclability being over 90%. By the year 2015, the directive under preparation is calling for an 85% recyclability rate and a 95% recyclability/re-use rate. Post-use phase After the usage phase, components can be reused and materials can be recycled or finally disposed of in a landfill. With forest machines, the primary option is to recycle the materials; the post-use share of the total environmental impact is minimal. 5 Eco-friendly technical solutions in John Deere harvesters Proportional lubrication system for saw unit The system adjusts lubrication according to saw speed, resulting in reduced consumption of lubricating oil. Gas discharge lamps (optio) The energy consumption of gas discharge lamps is one-third that of normal lamps. Moreover, gas discharge lamps offer good illumination and facilitate the operator’s work and reduce e.g. damage to the standing trees when working in low lighting conditions. TMC and Timbermatic 300 Optimized fuel and hydraulic efficiency when the parameters are set to the individual operator’s preferences. The parameters are operator-specified. John Deere offers training on how to specify the parameters. Stump treatment equipment Treating stumps can prevent the spread of root fomes. The stump treatment agent is sprayed on the stump’s cut surface through the flange. Silviculture districts and forest companies recommend the use of Phanerochaete gigantea fungus in stump treatment. When handling the stump treatment agent, the operator must wear a respirator and protective gloves and follow the mixing instructions provided. Color marking Speeds up the harvester’s work and thus reduces fuel consumption. Tires with a rounded shoulder profile for forest use The rounded shoulder profile of the tires is gentle on the forest floor. Extra-wide tires are available for special conditions. Eco-tracks can be used in the softest terrain conditions. Environmental package The Finnish Act on Combating Oil Pollution on Land (378/1974) obligates forest machine operators to prevent oil from being absorbed into the soil. Accordingly, an environmental package is available for John Deere machines. It contains e.g. oilabsorbent cloth or linen to help prevent oil from seeping into the nature and tools to remove polluted soil. 6 Viscous fan (optional) A viscous fan reduces fuel consumption and noise because the radiator fan is automatically used only when needed. Use of biodegradable products Technically, biodegradable products can be used in the engine cooling and hydraulic systems of all John Deere machines. Recyclability rate John Deere diesel engines Powerful, low-emission engine meeting emission standards. High torque at low rpm with very good fuel efficiency. Longer oil change intervals Oil change intervals (500 hours) have been doubled, resulting in reduced oil consumption. Hydraulic system The efficiency-optimized hydraulic system reduces fuel consumption because the need for cooling is decreased. Vacuum pump The pump produces negative pressure in the hydraulic system, preventing oil leakage from a damaged hose or open connector. Recycling must be technically possible and economically profitable. A product’s recyclability is measured in terms of its recyclability rate. The recyclability rate of a forest machine is determined by comparing the weight of the materials to be recycled to the total weight of the machine. The same approach is used with respect to the materials to be re-used and those to be disposed of. What are harvesters made of? The solid material composition of forest machines (% of total weight) Rubber 0.2%, non-recyclable Composite materials 3.4%, partially recyclable Plastics 1.7%, non-recyclable Battery 0.7%, recyclable Other materials 3.1%, partially recyclable Electronics 1.0%, non-recyclable Steel 65.5%, recyclable Tires (rubber + rims) 12.8%, recyclable Cast iron 11.2%, recyclable Other metals 0.4%, recyclable Harvester’s recyclability rate without fuel 92,4%. 92,4 % Recyclable materials 92,4% Non-recyclable materials 7,6% 7,6 % Harvester’s environmental impact during different phases of the life cycle 93.0% Usage 3.0% Production of materials 2.0% Maintenance and repairs 2.0 % Manufacturing of machine 0.001% Post-use disposal 100.0% Total The most significant environmental impact caused by a harvester during its life cycle is carbon-dioxide emissions, 499 000 kg. 7 Eco-friendly technical solutions in John Deere forwarders Design of machines and work lights The forwarder’s upward-narrowing load space and the design of the cab ensure good visibility to the tires and behind the machine. Good visibility helps the operator to avoid damaging the standing trees. The work lights, e.g. the extra lights placed at the end of the load space and the boom lights, are near the actual work area. TimberOffice: TimberNavi (optional) The harvester and forwarder can drive in the “same tracks.” Forwarder driving distances can be reduced with the help of timber and location data entered by the harvester operator. The harvester operator can also enter terrain data, such as soft soil areas, on the map. Additionally, the digital map shows the locations of the forested areas to be preserved. Hydraulic system The efficiency-optimized hydraulic system reduces fuel consumption because the need for cooling is decreased. Vacuum pump The pump produces negative pressure in the hydraulic system, preventing oil leakage from a damaged hose or open connector. Viscous fan (optional) A viscous fan reduces fuel consumption and noise because the radiator fan is automatically used only when needed. John Deere diesel engines Powerful, low-emission engine meeting emission standards. High torque at low rpm with very good fuel efficiency. 8 Tires with a rounded shoulder profile for forest use The rounded shoulder profile of the tires is gentle on the forest floor. Extra-wide tires are available for special conditions. Eco-tracks can be used in the softest terrain conditions. Longer oil change intervals Oil change intervals (500 hours) have been doubled, resulting in reduced oil consumption. Hydrostatic power transmission Ensures a smooth start and drive. Can be adjusted according to the terrain. John Deere ALS solution The solution optimizes driving distances and speed, resulting in reduced fuel consumption. The lower lifting height when loading and unloading also reduces fuel consumption. The stabilizing features of the ALS solution significantly reduce load swing, resulting in optimal speed for fuel economy. Environmental impact assessment John Deere forwarder’s environmental impact during different phases of the life cycle Loader-mounted scale (optional) Available for the latest forwarder models, a loader-mounted scale helps optimize the load size and thus minimize terrain-damaging overloads. 88.0% Usage 5.0% Production of materials 4.0% Maintenance and repairs 3.0% Manufacturing of machine 0.0% Post-use disposal 100.0% Total The most significant environmental impact caused by a forwarder during its life cycle is the carbon-dioxide emissions, 509,100 kg. Forwarder’s recyclability rate 92,4 % Recyclability rate 91.8% Re-use rate 4.8% 4,8 % Post-use disposal rate 3.4% 3,4 % Forwarder’s rearview camera (optional) With the rearview camera, the operator has an unobstructed rear view – even with a full load. Low ground pressure with balanced bogie solution Reduces pressure on the soil and undergrowth. A built-in balancing unit constantly distributes weight as evenly as possible between both bogie wheels. Bogie design The generous ground clearance of John Deere’s wide bogie design makes it easier to maneuver at harvesting sites and thus reduces ground damage. 9 Slash bundler: Wood energy to counteract climate change With energy consumption constantly on the rise and fossil fuels becoming exhausted, one of society’s big challenges is to try to control global warming. Increasing the use and efficiency of renewable energy sources like biofuels is one solution to curbing climate change. Biofuels, like wood and straw, are renewable, bio-based and carbon dioxide-neutral sources of energy. John Deere has developed its own solution for harvesting logging residuals and small trees. Rather than chipping energy wood in the forest, a slash bundler compresses the residuals into bundles that are easy to store and to transport. One bundle = ½ barrel of oil In the bundling method, the logging residual and slash left behind by the harvester at the logging 10 site are collected and fed into a bundler that sits on a forwarder chassis; the bundler compresses the logging residual into cylindrical bundles called slash logs. The bundling process is continuous and not restricted by the length of the energy wood. The length of the slash bundle can be optimized to accommodate the transport equipment. The slash bundler automatically keeps a real-time record of the number of bundles produced. The bundles are standard sizes, so the exact amount of fuel being stored is known. One bundle normally weighs 500-700 kg and contains about 1 MWh of energy, or the equivalent of about a half a barrel of oil. After bundling, a forwarder transports the slash logs from the forest to the road-side, where a standard logging truck picks them up and takes them to the power plant. Thus the transporting of the bundles doesn’t require special equipment; the slash logs go through the same logistics chain in the forest as saw logs and pulpwood. Storing the bundles is clean and easy. The dense bundles do not decompose easily so they can be stored either in the forest or at the power plant for use during peak periods of energy production. The bundles dry well also when stacked. Test results show that the bundling method is very suitable for different species of trees and a variety of working conditions. Not only has the method brought the recovery of bioenergy into the spotlight, it has also shed light on other advantages: the recovery of logging residuals, for instance, significantly reduces the risk of forest fires. Forest chip production chains are generally very efficient, consuming about 2–3% of the energy content of the fuel produced and with low greenhouse gas emissions (Wihersaari & Palosuo 2000. Puuenergia ja kasvihuonekaasut. Osa 1. VTT Energian raportteja 8/2000) [Wood energy and greenhouse gases. Part 1. VTT Energy reports 8/2000]. John Deere 1490D Slash Bundler Gross weight Engine output Boom reach Maximum travel speed Capacity 22–24 t 136 kW 10 m 22 km/h 10–30 bundles/h Bundle Length 3 or 3.2 m Diameter 70–80 cm Energy content 1 MWh Life cycle phases and their relative environmental impact The different phases of a John Deere slash bundler and the percentages of their total environmental impact. (Eco-indicator 95) Wood is clean energy Wood is considered a carbon dioxide-neutral source of fuel because planted trees have the ability to absorb carbon dioxide as part of photosynthesis. The carbon dioxide remains in the tree until the wood decomposes or is burned; it then releases the same amount of carbon dioxide that was initially absorbed. Thus the amount of carbon dioxide in the atmosphere does not increase. Wood-based biofuels include logging residuals from the forest industry, by-products of the wood-processing industry, such as bark, sawdust, woodchips and black liquor, and recycled chips. Generally, the by-products of the wood-processing industry are already being utilized quite efficiently, but the use of logging residuals could be increased substantially. There are still plenty of opportunities to increase the use of wood fuels. For example, the goal of the energy and climate strategies in Finland is to increase the use of wood fuel by 15 million solid cubic meters by the year 2010. The aim is for one third of this amount, or 5 million solid cubic meters, to come from forest chips. In 1999 forest chips accounted for less than 3 percent of the wood fuel used in Finland. 88.7% Usage 5.6% Production of materials 3.3% Maintenance and repairs 2.3% Manufacturing of machine 0.1% Post-use disposal 100.0% Total The most significant environmental impact caused during a slash bundler’s life cycle is the carbon-dioxide emissions, 727,000 kg. Recyclability rate The slash bundler sits on a forwarder chassis that has a bundler component and the necessary automation attached to it. The recyclability rate of a forwarder is 91.8%, its re-use rate 4.8%, and its final disposal rate 3.4%, which is very similar to the recyclability rate of a slash bundler. 11 Traces of forest machines in the environment – in the atmosphere and in the forest Forest industry companies, forest owners, forestry and other regulations, forest and environmental centers, forest certifications…. Many interests govern the way in which trees are harvested – also in a proenvironment light. Forest centers annually survey different harvesting and silviculture sites through random samplings. These surveys use methods developed by the Forestry Development Center Tapio in Finland. The surveys focus on issues like damage to the terrain and the damage to residual forests in thinnings. In addition to the emissions taxing the environment, the use of forest machines leaves traces in the forest nature – the trunks of the remaining trees and roots may be damaged and other vegetation may suffer from the ground pressure caused by the machine and the load, particularly when the soil is not frozen. A forest machine with no load puts about the same pressure on the soil surface as an adult man. This is a result of carefully thought out factors related to center of gravity, weight distribution and tire profiles. 12 The right size machine in the right place at the right time – i.e. a harvesting plan developed by the forest owner and takes environmental aspects into consideration to reduce the environmental impact. John Deere offers the market’s widest range of forest machines to choose from and the right solution has been developed for different harvesting sites. The harvesting plan must take into consideration the forestscapes and important habitats defined in nature conservation and forestry legislation as well as the groups of trees and decaying trees saved in clear felling to support forest biodiversity. Following a carefully planned driving path can significantly decrease the traces left behind in the forest. Not breaking the ground surface helps to prevent solid materials and nutrients from being washed into water bodies. Untouched protective zones on the shores of bodies of water are important in terms of scenery, but they also filter the water run-off from felling areas. When logging in predominantly coniferous forests, the prevention of injurious fungus, such as root fomes, must also be addressed. Stump treatment is done between May-November. Use of most com- mon herbicides is safe and easy with harvester heads, but the instructions provided by the manufacturer must be followed and the necessary protective gear must be used. The operator’s professional skills and ability to estimate and control machine movement helps minimize damage to the residual forest and other vegetation. Machines with good control and ergonomic solutions make the work of operators easier. TMC and Timbermatic 300 systems, e.g., can help optimize fuel and hydraulics oil consumption. It is absolutely forbidden to pollute the groundwater also in the forest. When handling oil products used in forest machines, very close attention must be paid in groundwater areas and the soil surface must not be damaged unnecessarily when harvesting trees. The machines have an environmental package for cleaning oil spills. Waste must be disposed of properly also at logging sites. How logging residual recovery affects the forest environment The Finnish Forest Research Institute has studied the effects of logging residual recovery on the forest soil and environment in Finland (Finnish Forest Research Institute Research Papers 816, 2001). Noteworthy between the study results and the methods that are already standard practice is that the studies assume recovery of all biomass. In fact, about 60-70% of the logging residual is recovered. The biomass left on the ground consists primarily of small, nutrient-rich twigs. The results of the study are presented below. Forest regeneration and soil nutrients Thanks to the recovery of logging residuals, the forest regeneration chain can be accelerated by as much as two years. Optimally, clear felling, soil cultivation, and reforestation can take place during a single growing season. This lessens the damage to the growing saplings by the competing ground cover. It is estimated that also soil cultivation and planting work leads to better results in areas without logging residuals than in areas where logging residuals have not been recovered. It can be estimated that the recovery of logging residuals shortens regeneration time, decreases regeneration costs, and furthers the mechanization of forest cultivation. By contrast, the recovery of fresh logging residuals from clear-felling areas means that a substantial amount of nutrients are removed from the growing site. But the share of this removal of the total nutrient cycle is not critical in light of a tree’s life expectancy, which is about 80 years. The nutrient need of the saplings in the regeneration area is small for years, so the risk of nutrients being washed away during this period is substantial. When carried away by surface water, nutrients can strain neighboring water systems. Some studies show that recovery of logging residuals from clear-felling areas decreases the growth in length of planted spruce saplings. The decrease is the equivalent of an average of two years of growth. Based on tests conducted in Sweden, it has been concluded that the stunted growth corresponds to the period when nitrogen is released from the logging residuals for use by the vegetation. The recovery of logging residuals has had no noticeable effect on the growth in the length of pine. The possible effects of the recovery of logging residuals on the nutrient cycle of the forest soil can be offset by fertilizing, for example, by returning the ash from the burnt wood to the forest. Forest biodiversity and forest damage The effect of the recovery of logging residuals on the forest environment is very small when compared to the effects of clear felling. The decrease in decomposing wood is the single main factor decreasing the biodiversity of commercial forests. Some logs are intentionally left to rot in the forest during harvesting and are not recovered with the logging residuals. A larger-diameter decaying tree is more important for the biodiversity of the species than small-diameter treetops and branches, so it is good to exclude the larger-diameter decayed wood from the logging of energy wood. Regardless, some 25-35% of the small-diameter logging residuals are left in the forest for logging technology reasons. Based on studies to date, it seems that the one-time recovery of logging residuals in conjunction with clear fellings or thinnings does not have a permanent impact on the forest soil of the growing area. The studies are continuing so that the effects can be evaluated over a period of several tree generations. It is estimated that in the short-term the recovery of logging residuals does not have a significant effect on insect damage and disease to the forest. If the logging residuals are recovered from the same area over several tree generations, the diversity of mushroom species decreases. Consequently, it can be assumed that the risk for diseases would grow. The risk for insect damage caused by the logging and storing of energy wood can be reduced by timing the logging and transporting in accordance with the regulations concerning the prevention of forest damage. Forestscape and recreational use of forests The surrounding scenery is fundamental to the recreational experience of a hiker in the forest. Most people think that logging residuals generally reduce the scenic value of a forest. Moreover, logging residuals hamper mobility in forests as well as berry and mushroom picking. People like a forestscape that is easily accessible. The recovery of logging residuals from the felling area improves the visual quality of the landscape and makes it easier to move about in the forest. 13 14 A healthy forest is the best alternative Knowledge of the environment is one of biggest competitive factors for machine contractors in the logging business. John Deere offers a wide selection of forest machines – different solutions for different logging sites. Technical solutions play a very supportive role in the reduction of emissions and environmental impact on the forest habitat. The eco-awareness of the forest machine operator is another very important factor. It is ultimately up to the operator to decide how he will utilize the technical solutions when working at a logging site. Healthy, vital and diverse forests are the best alternative for everyone operating in the forest industry. When it comes to environmental issues, the right attitude is critical. Operators also need up-to-date information on environmental issues and they need to know how the way they perform the job can minimize the impact the environment. Forest machine owners can choose accessories that boost efficiency and productivity and also reduce the environmental impact. The best solutions and working methods for the environment are often the most cost effective. John Deere harvesters John Deere 770D is a small and agile harvester for thinning and for regeneration harvesting of small diameter trees. John Deere 1070D is a harvester suitable for later thinning and can handle lighter regeneration harvesting with ease. John Deere 1110D is a versatile all-around performer for thinning and regeneration harvesting, and is also suitable for soft-soil conditions. John Deere 1410D is a powerful forwarder with big load capacity, thus requiring fewer site-tostorage hauling trips. The 1410 is suitable for regeneration harvesting as well as later harvesting. John Deere 1270D is productive and reliable machine for thinning and regeneration harvesting. The 1270 model is currently the world’s most popular harvester. John Deere 1710D is a powerful forwarder designed to work under extreme conditions. It can handle long driving distances with a full load. John Deere 1470D is designed for the toughest regeneration harvesting applications in stands with the heaviest trees and challenging terrain. John Deere slash bundler Additional information: John Deere Forestry Oy P.O. Box 474 FI-33101 Tampere Tel. +358 20 584 162 Finland www.deere.fi [email protected] John Deere 1490D is a slash bundler that collects, compresses and bales logging residual for transportation. The integrated TMC unit controls and monitors the bundling process. John Deere forwarders John Deere 810D is the least environmentally taxing of all forwarders on the market. Superb weight distribution and balance make this forwarder suitable for use also on soft terrain. John Deere 1010D is used for thinning and for regeneration harvesting. Its six wheels give it extreme agility, making it easy to avoid damaging trees even in thinning work. 15 Compositor/Typeworks/Lönnberg Painot 2006
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