7th September 2016: Session C5 Timber harvesting 2
Long range Cable Systems in Japan:
Succession and
Continuous Development to Overcome
Terrain and Cost Balance
Yasushi Suzuki*, Shin Yamasaki**, Toshihiko
Yamasaki**, Hisashi Ishigaki ***
*: Faculty of Agriculture and Marine Science, Kochi University, Japan
E-mail: : [email protected]
**: Kochi Prefectural Forest Technology Center
***: Tosa Reihoku Co. Ltd
September 4th-7th , 2016
Warsaw University of Life Sciences,
and Puławska Residence Hotel,
Warsaw , Porland
FORMEC2016: The 49th International Symposium on Forestry
Mechanization
1
Contents
• Background
– Role of logging cable systems in Japan
• Overview
– Endless-Tyler system
– Collector system
– H-type system
• Operational efficiency and cost analysis
• Conclusions
2
Ara of Japanese forestry
Nakagawa (2016)
Recovery
Mass
after War
plantation
Commercial
thinning
Clear cut &
regeneration
1000 JPY =
38 PLN
10 USD
(Aug. 31,
2016)
• Recovery -> Mass plantation -> Thinning
• Log price coincides with domestic demand
Source: Forestry Agency (2016) Annual Report on Forest and Forestry in Japan - Fiscal Year 2015: 243pp, Ministry of Agriculture, F orestry, and
3
Fisheries (MAFF), Tokyo.
Nakagawa, K. (2016) Forestry technologies of next generation for revitalization of forests*: 205pp, Forest-culture Japan, Tokyo (in Japanese).
Cable logging machines
Stational
yarder: Large
Small
10
Num. (x1000)
• Conventional yarder:
Decreasing
• Swing yarder
(Japanese style):
Increasing
• Tower yarder:
European, imported
Span:
500m <
5
Self-propelled
Up to 100m
carriage
Swing yarder
0
Tower yarder
1990
2000
100 – 300m
2010
Source: Forestry Agency (2016) Annual Report on Forest and Forestry in Japan - Fiscal Year 2015: 243pp, Ministry of Agriculture,
F orestry, and Fisheries (MAFF), Tokyo.
4
Proportion of terrain on forest area
Long range cable system
Cable system
Truck
Gentle
( < 20%)
Tractor
Medium
(20-40%)
Steep
(40-70%)
Very steep
(70% <)
• Ca. 50% is suitable for cable system.
Source: Hori, T. (1965) “A Classification of Ground Configuration for Logging Planning,” Journal of the Japanese Forestry Society, 47, 168-170
(in Japanese).
5
Sakai, T. (2000) “Geographical features of Japanese forest,” Journal of the Japan Forest Engineering Society, 15, 221-224 (in Japanese).
Road network status and operation system
Proposed by Gotou (2011, 2016)
Conventional system
Road network status
Distance
between
main
Road
roads
density
（m）
（m/ha）
［Roundab
out rate］
Truck
ca. 25
road
1000 [2.6]
Truck
ca. 50
road
500 [2.2]
Truck
road
ca. 75
250 [1.7]
Forwarder
ca. 100road
150
120 [1.4]
Forwarder
road
ca. 200
60 [1.2]
Fine road
network
Yes
No
Yes
Average slope gradient （within a circle of main-road-distance diameter）
Gentle
Medium
(less than
(1515 deg.) 30deg.)
Steep (30-35
deg.)
Swing yarder
Middle sized (Base
machine bucket
capacity 0.45m 3)
Middle range
cable system
Self-propelled
carriage
Very steep
(more than
35 deg.)
No
Yes
No
Yes
No
Tractor-Winch
Grapple-Forwarder
Middle sized (Base
machine bucket
capacity 0.45m 3)
Harvester
Swing yarder
Small sized
Grapple- 2tTruck
Small sized
(Base
machine
bucket
capacity
0.25m 3)
• Cable system has its role.
Gentle
Medium
(less than
(1515 deg.) 30deg.)
Tractor-Winch
Middle sized
No
Yes
New system
Long range
conventional
calbe system
Harvester
Middle sized
Harvester,
Large
sized
Steep
(30-35
deg.)
Tower
yarder
Middle
sized
Tower
yarder
Small
sized
Very steep
(more than
35 deg.)
Conventional
cable system
Tractorwinch Tower yarder
Small
Large sized
sized
6
Source: Suzuki, Y., Setiawan, A.H. and Gotou, J. (2015) Timber harvesting systems in Japan’s aging plantation forests: Implications for
investment in construction of forest road networks. Journal of the Japanese Forest Society 97:191-202 (in Japanese with English summary).
Cable system 1: Endless-Tyler System
Tail spar
Head spar
1 2
3
Skyline
Carriage
LTL
(Lifting line)
Yarder
(Three drums)
Loading block
Logs
ELL
(Endless line)
HBL (Haul back line)
• Standard cable logging system in Japan
• HBL: Lateral logging to enlarge logging area
– Mainly for clear cut
7
Practical case: Endless-Tyler
• Clear cut
– Broad-leaved trees
– Biomass use: Power generation
4
(0.52ha )
0.54ha
0.66ha
1,90ha
1.80ha
1.36ha
Landing Yarder
• Test operation
0
300m
– Efficiency
– Cost analysis
Source: Suzuki, Y., Yamasaki, S., Watanabe, N., and Fukuda, Y. (2016) “Productivity and cost efficiency of a cable logging operation at a
clear cut broadleaved forest stand to supply feedstock for woody biomass electric generation,” Journal of the Japan Forest Engineering
8
Society, 31, 85-91 (in Japanese with English summary).
Felling (Broadleaved, Clear-cut)
Logging
Landing
Loading (Biomass)
9
Endless Tyler
← to Landing
Tail spar
Source: Kochi Prefecture (2010) Efficient logging by collector logging cable system. (in Japanese)
Endless Tyler:
Damage to residual stands
← to Landing
Source: Kochi Prefecture (2010) Efficient logging by collector logging cable system. (in Japanese)
Tail spar →
2: Collector System
SKL (Sky line)
CR (Carriage)
CB
(Lifting line) LFL
LB
(Loading
block)
(Haul back
line)
(Collector
operation
COPL
line)
HBL
YD (Yarder)
(Collector
block)
(Endless line) ELL
• CB controls swinging of HBL
• Arrangement of Endless-Tyler for thinning
12
Collector system: Lateral logging
← to Landing
CB
Tail spar →
• CB
controls
movement
of HBL
HBL
Source: Kochi Prefecture (2010) Efficient logging by collector logging cable system. (in Japanese)
• Yarder
with 3 axis
and 4
drums
Collector system: Loaded logging
← to Landing
Tail spar →
• Good for
line
thinning or
fish-bone
thinning
HBL
Source: Kochi Prefecture (2010) Efficient logging by collector logging cable system. (in Japanese)
• Rearrange
ment of
HBL is
required
for line
change
Practical case:
Collector system
Site
Operated
Forest road
Paved road
• Specifications
–
–
–
–
Skyline
Landing
Plots
Head
spar
P1
Span: 500m
Skyline: 22mm
Payload: 800kgf
Full-tree, Processor
• Site
– Area: 2.25ha
– Nov. 2009 – Feb. 2010
P2
• Work study
Tail
spar
0
500m
– P1: 0.34ha (P2: winching)
– Jan. 7, 8, 14; 2010
0
500 m T., Nakaya, T. and Toda, A. (2011) “Operational
Source: Suzuki, Y., Suzuki, Y., Gotou,
J., Sugimoto, J., Yamasaki, T., Yamaguchi,
efficiency and residual stand damage by a collector-cable-logging method for thinning operations,” Journal of the Japan Forest
Engineering Society, 26, 163-172 (in Japanese with English summary).
15
CB: Collector block
CR: Carriage
LB: Loading block
Blocks for HBL on mountain side
16
Felling (Fish borne)
Lateral logging
Yarder (SK50-4A)
Processor (CAT312C +
CM-40Z)
Processing at the landing
Loaded main logging
17
3: H-type system
B1
B2
Tail spars
Skyline 2
Carriage 2
(CR2)
Skyline 1
Carriage 1
(CR1)
Lifting
line 1
A2
Lifting line 2
A1
Loading
block
(LB)
• Two sets of normal system
• Connected at loading block
• Large area, vertical lifting
Head
spars
Yarder
(4-Drums)
•
Thinning, single tree selection
Source: Reihoku Forestry Office, Kochi Precture (1998) Rigging examples of H-type cable logging systems*, 6pp, Reihoku Forestry Office, Kochi
Prefecture, Motoyama-town (in Japanese). * The title is a tentative translation from original Japanese by the authors.
18
Practical case: H-type system
0
• Average span: 1060m
• Multiple sets / Site
700m • Ave. 230ha/Site
19
Skyline 1
Landing
Skyline 2
• 3.2Sets/Site
• 14ha/Set
• 98m3/ha
4-Drum yarder; Newly developed
Residue recovery
20
Skyline 1
→
Productivity and cost:
Logging and processing
Productivity y (m3/crew-hour)
z = 1000 z = 2,500
z = 5,000 JPY/m3
4
z = 7,500
3
Endless-Tyler
(Clear Cut)
Collector
H-system
2
z = 10,000
1
0
0
10
20
Hourly cost x (1000 JPY/crew-hour)
1000 JPY = 38 PLN
10 USD
(Aug. 31, 2016)
Note: Resultant cost z (JPY/m3) = [Hourly cost x (JPY/crew-hour)] / [Productivity y (m3/crew-hour)].
Error bars indicate Max. and Min.
• Resultant cost: Collector = Endless Tyler
• H-system: High productivity, low resultant cost
21
Cost and income
Rigging
*
Endless-Tylar: Cost
Felling
Collector: Cost
Logging and
Processing
Transportation
H-system: Cost
Endless-Tylar:* Income
Collector: Income
Log
H-system: Income
Residue
0
*:
Clearcut, broad leaved trees
10
1000 JPY/m3
20
Subsidy
1000 JPY = 38 PLN
10 USD
(Aug. 31, 2016)
• H-system: Low cost due to low rigging cost
• Collector income: Thinning subsidy + Biomass
22
Conclusions
• Steep terrain, matured forest
– Need for long range cable system (500m < Span)
• Development
– Lateral logging: Endless-Tyler + HBL
– Thinning: Collector
– Large area, vertical lifting: H-system
• Cost balance
– Thinning subsidy, Biomass, High efficiency
23
Acknowledgement and Notification
• Funded by: JSPS KAKENHI Grant
Numbers 15H04508 and16K07779
• Notice: IUFRO Meeting 2017 Summer
– Joint Regional Meeting of IUFRO RG3.03.00
and RG3.06.00 in Asia: Productivity and
Safety of Final Cutting on Mountain Forests
July 24th-28th, 2017
Ehime & Kochi,
Japan
http://www.kochi-u.ac.jp/iufrojrm/
24
25
Results: Productivity and cost
26
Balance of operational cost and
productivity
• z =x/y
x = hourly cost (103JPY/crew-hour)
y = Productivity (m3/crew-hour)
z = Resultant cost (103JPY/m3)
z : Resultant cost (103JPY/m3)
x: hourly cost (103JPY/crew-hour)
y: Productivity (m3/crew-hour)
• Resultant cost z is expressed as equivalent lines on the
coordinate of hourly cost x and productivity y
x: hourly cost (103JPY/crew-hour)
27
z (Resultant cost) = 500 (JPY/m3)
a
d
z = 1000
b
c
z = 2000
z = 5000
x: hourly cost (103JPY/crew-hour)
y: Productivity (m3/crew-hour)
y: Productivity (m3/crew-hour)
Balance of operational cost and productivity
Mean
Cable system
Swing yarder
Grappling
Winching
Grappling & Winching
2,000 JPY/m3
5,000
10,000
20,000
50,000
x: hourly cost (103JPY/crew-hour)
Fig. Relationship among productivity (y), hourly cost Fig. Relationship among productivity (y), hourly cost
(x), and resultant operational cost (z)
(x), and resultant operational cost (z) on logging
Note: z = x / y
and bucking operation
Note: z = x / y
•
If investment on machine (x -> up) results in higher productivity (y -> up), resultant
operational cost will be down (a)
–
•
When productivity did not much the investment, resultant cost would be even higher (b)
With less investment (x -> low), not bad productivity would result in lower cost (d)
–
If less investment makes productivity too lower (y -> down), resultant cost would be higher (c)
Figure source: Setiawan, A.H., Suzuki, Y., and Gotou, J. 2013. Classification of forest operations with regard to hourly cost to productivity balance - A
proposal of a framework for analysis of the relationship between hourly cost and productivity using a simple chart -. Journal of the Japan Forest 28
Engineering Society 28:143-148.