Load and Unload Technology to Improve Round-Bale Hauling Efficiency

There are two key parameters in short-haul truck operations to deliver biomass to a biorefinery: (1) mass of the load and (2) cycle time (load, travel, unload, and return). A plan to optimize both these parameters is outlined in this study. Operation of a logistics system to deliver 20-bale racks to a biorefinery for continuous 24/7 operation, 48 weeks/year is described. Round bales are stored in satellite storage locations (SSLs) by feedstock producers. A truckload consists of two tandem trailers (40, 0.4 Mg bales), a specification that maximizes load mass. Load-out at the SSL (loading bales into racks) is performed by a contractor and paid by the biorefinery. Subsequent hauling (truck tractor to pull the trailers) is also contracted for by the biorefinery. Central control is specified; the “feedstock manager” at the biorefinery decides the order SSLs are loaded out and can route a truck to any SSL where a load is ready. Tandem trailers with empty racks are dropped at the SSL, and the trailers with full racks are towed to the biorefinery. Uncoupling the loading and hauling in this manner reduces the time the truck waits for loading and the SSL load-out waits for a truck; thus, productivity of both operations is increased. At the biorefinery receiving facility, full racks are removed from the trailers and replaced with empty racks. The objective for this transfer is a 10 min unload time, which completes a logistics design that minimizes cycle time. A delivered rack is placed in a rack unloader to supply bales for immediate processing, or it is placed in central storage to supply bales for nighttime and weekend operations. Three biorefinery capacities were studied: 0.5, 1.0, and 1.5 bale/min. The analysis shows that rack cost to supply a biorefinery processing a bale/min for 24/7 operation is ~3.00 USD/Mg of annual biorefinery capacity, and the rack trailer cost is ~3.25 USD/Mg. Total delivery cost, beginning with bales in SSL storage and ending with a rack being placed in an unloader to deliver individual bales for processing, is 31.51, 28.42, and 26.92 USD/Mg for a biorefinery processing rates of 0.5, 1.0, and 1.5 bale/min, respectively