Paint and Final AssemblySystemsGreen PaintshopStatus Quo and Future PerspectivesDr. Frederic de MolièreBarcelona, November...
Our Customers Go For Green… because  Sustainability and environment protection are important  steps to protect our future ...
Our Customers Go For Green“The future will define ‘Premium’ bythe degree of sustainability.”Dr. N. Reithofer, BMW“Reduce C...
Green PaintshopMain factors of ecological sustainability© Dürr Systems GmbH, Green Paintshop, November 2011   -4-
CPU Saving PotentialsEnergy costs: 7 - 13% of total cost                       Traditional paint shop                     ...
Our Customers go for Green How fare?   Changchun   Abatement: primer,   BC,CC   Györ                                 Inves...
Utility Calculation ToolCalulation programs Proc_Oven                                                                    U...
Utility Calculation Tool   Plant Design – Process Definition   Plant Design – Process Definition                         C...
Utility Calculation Tool         Plant (ID-No.)         Plant (ID-No.)             Electrics                              ...
Energy: Dürr’s Green Paintshop SolutionsEnergy benchmark: 430 kWh per body (60 jph)General Paintshop                      ...
Energy Consumption                                             (Examples)               kWh/unit                          ...
Energy Consumption: Sensitivity AnalysisSite (examples)                                                                   ...
Energy consumption: Sensitivity AnalysisProduction rate (examples)           kWh/unit                 800                 ...
Energy Consumption: Sensitivity AnalysisWorking hours/day (examples)           kWh/unit                                   ...
Energy Consumption: Sensitivity AnalysisFirst run rate (examples)           kWh/unit                                      ...
Energy Saving PotentialsBasis: Dürr’s Green Paintshop Reference (BMW Shenyang)                                China       ...
CO2: Dürr’s Green Paintshop SolutionCO2 benchmark: 141 kg/unit    CO2 calculation    1.   Electrical energy               ...
CO2 Emission                                    (Examples)                kg/unit                                         ...
VOC: Dürr’s Green Paintshop SolutionVOC abatement benchmark: 2,3 g/m2                                                     ...
VOC: Emission Examples                g/m2                           Norsom                                               ...
Dürr’s Green Paintshop SolutionsWater consumption benchmark: 396,9 l/unit            EcoFilter-Oil-UF                     ...
Water Consumption                                         (Examples)                                       Dalian         ...
Water Consumption                                               (Examples)                  l/unit                   700  ...
Dürr’s Green Paintshop SolutionsWaste water benchmark: 160 l/unit           EcoDryScrubber                                ...
Dürr’s Green Paintshop SolutionsMaterial consumption benchmark: 118,5 €/unit                                              ...
Material Consumption                                           (Examples)                                         Traditio...
Green PaintshopMain factors of ecological sustainability© Dürr Systems GmbH, Green Paintshop, November 2011   - 27 -
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Frederic de Molière - Paint and Final Assembly Systems. Green Paintshop. Status Quo and Future Perspectives

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Paint and Final Assembly Systems. Green Paintshop. Status Quo and Future Perspectives

By Frederic de Molière

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Transcript of "Frederic de Molière - Paint and Final Assembly Systems. Green Paintshop. Status Quo and Future Perspectives"

  1. 1. Paint and Final AssemblySystemsGreen PaintshopStatus Quo and Future PerspectivesDr. Frederic de MolièreBarcelona, November 16-17, 2011
  2. 2. Our Customers Go For Green… because Sustainability and environment protection are important steps to protect our future Increasingly, governmental regulations reflect serious intentions OEMs are committed to ecology, economy and society Green image of OEMs is increasingly important Identification of customers with Environmental product/OEM Increasing sales volume OEMs want to control costs for ecology Economical Social© Dürr Systems GmbH, Green Paintshop, November 2011 -2-
  3. 3. Our Customers Go For Green“The future will define ‘Premium’ bythe degree of sustainability.”Dr. N. Reithofer, BMW“Reduce CO2 in production by 40%until 2020“(VW, Mr. Klingler 9/11)“Chinese car manufacturers to reduceenergy consumption for production byyearly 5%”© Dürr Systems GmbH, Green Paintshop, November 2011 -3-
  4. 4. Green PaintshopMain factors of ecological sustainability© Dürr Systems GmbH, Green Paintshop, November 2011 -4-
  5. 5. CPU Saving PotentialsEnergy costs: 7 - 13% of total cost Traditional paint shop Benchmark BMW Shenyang Total CPU = 340,3 €/unit Total CPU = 318,5 €/unit Investment Material Material Investment 19% 38% 38% 23% Energy Energy Maintenan 13% 7% Maintenance ce 3% 3% Personell Personell 29% 27%© Dürr Systems GmbH, Green Paintshop, November 2011 -5-
  6. 6. Our Customers go for Green How fare? Changchun Abatement: primer, BC,CC Györ Investment Abatement: primer, Investment BC,CC CPU BMW Shenyang Green Abatement: BC,CC ROI=30y solution ROI=1y Investment Investment ROI > target ROI < target ROI=6y Private households Changan Solar energy systems Heat recovery after oven Shenyang Changchun Shenyang Marocco Hot water heat exchanger (pure gas Heatwheels Heatwheels Heat recovery after oven oven)© Dürr Systems GmbH, Green Paintshop, November 2011 -6-
  7. 7. Utility Calculation ToolCalulation programs Proc_Oven Utility_mech Utility_mech Proc_Oven oven oven hot water hot water cooling zone cooling zone cold water cold water Summary Summary gas gas compr. air CPU CPU Basic_Data Basic_Data compr. air Proc_Booth Proc_Booth DI water DI water booth file structure file structure booth work decks general data general data work decks change management Ener_el Ener_el shop ventilation shop ventilation change management operation power operation powerForm sheets lightning lightning ED rectifier ED rectifier Utility_Wet Utility_Wet PT PT EC EC Utility_Water Utility_Water Utility_Other Utility_Other DI water plant DI water plant waste water plant waste water plant external energies external energies© Dürr Systems GmbH, Green Paintshop, November 2011 -7-
  8. 8. Utility Calculation Tool Plant Design – Process Definition Plant Design – Process Definition Climatic Conditions (Min, Max, Dispersion) Climatic Conditions (Min, Max, Dispersion) Definition of temperature and humidity areas to get 12 representative time-weighted conditions. Air ducting Air ducting Process Window – Booth/Shop conditions Process Window – Booth/Shop conditions Calculate for each representative condition Calculate for each representative condition Calculation of heating/cooling capacity Calculation of heating/cooling capacity energy consumption to get average values energy consumption to get average values Dimensioning of components Dimensioning of components (pumps, fans, tanks, wet/dry scrubber, heat recovery) (pumps, fans, tanks, wet/dry scrubber, heat recovery) Shift model (operation hours) Shift model (operation hours)© Dürr Systems GmbH, Green Paintshop, November 2011 -8-
  9. 9. Utility Calculation Tool Plant (ID-No.) Plant (ID-No.) Electrics Electrics Hot water Hot water Cold water Cold water Gas Gas CA CA DI water DI water Limestone Limestone PT PT EC EC EC Oven EC Oven Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Connection Connection Connection Connection Connection Connection Connection Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Consumtion Primer Booth Connection Connection Connection Connection Connection Connection Connection Primer Booth Primer Oven Primer Oven TC Booth TC Booth TC Oven TC Oven Application Application Conveyor Conveyor x 92*) Shop Ventil. x 92*) Shop Ventil. 3 //3 total energy consumption total energy consumption //total bodies total bodies *) 1000 Nm³ = 92 kWh energy consumption per body energy consumption per body© Dürr Systems GmbH, Green Paintshop, November 2011 -9-
  10. 10. Energy: Dürr’s Green Paintshop SolutionsEnergy benchmark: 430 kWh per body (60 jph)General Paintshop Lean Layout EcoEmos Energy Ecopaint RoDipSettings Site Product (m2) Skid length jph (gross/net) Rest PT 14% PT/EC Working hours/day Optimized EcoTunnel air Building 11% seal Lean Process EC 10% Combined heat and power Work decks 13% EcoDryScrubber Booths 13% Ovens 31%Shop Ventilation/Work Decks Ovens TAR + Tarcom V Booths Heat exchanger Straight pass oven Reduced size (RPE) Heat wheels Reduced down draft Optimized air Extended heat up time Optimized air exchange rate Exchange rates Asymmetric holding zone 2nd filter stage in plenum One filter stage only© Dürr Systems GmbH, Green Paintshop, November 2011 - 10 -
  11. 11. Energy Consumption (Examples) kWh/unit Total energy saving potential USA worldwide for reduction by 400 1000 900 kWh/car ( 75 Mio cars/year): 900 Ungary - 5 nuclear power plants China 800 790 740 China China 700 650 600 600 USA BMW China 500 470 430 400 300 200 100 Traditional paintshops Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 11 -
  12. 12. Energy Consumption: Sensitivity AnalysisSite (examples) - 59 kWh/unit Germany Shenyang - 59 kWh/unit Yantai - 97 kWh/unit Brazil© Dürr Systems GmbH, Green Paintshop, November 2011 - 12 -
  13. 13. Energy consumption: Sensitivity AnalysisProduction rate (examples) kWh/unit 800 Changsha 738 700 - 145 kWh/unit Shenyang 600 593 - 40 kWh/unit 500 470 430 400 300 200 100 30 jph 60 jph 30 jph 60 jph© Dürr Systems GmbH, Green Paintshop, November 2011 - 13 -
  14. 14. Energy Consumption: Sensitivity AnalysisWorking hours/day (examples) kWh/unit - 70 kWh/unit 600 500 400 300 200 100 16 h/day 24 h/day© Dürr Systems GmbH, Green Paintshop, November 2011 - 14 -
  15. 15. Energy Consumption: Sensitivity AnalysisFirst run rate (examples) kWh/unit - 5,6% (- 42,5 kWh/unit) 600 500 400 300 200 100 First run rate 85% First run rate 90%© Dürr Systems GmbH, Green Paintshop, November 2011 - 15 -
  16. 16. Energy Saving PotentialsBasis: Dürr’s Green Paintshop Reference (BMW Shenyang) China kWh/unit Shenyang China 30 jph Shenyang 500 60 jph 470 Germany Brazil 430 60 jph 60 jph 400 371 333 300 200 100 Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 16 -
  17. 17. CO2: Dürr’s Green Paintshop SolutionCO2 benchmark: 141 kg/unit CO2 calculation 1. Electrical energy 55.500 MWh/a Cold water1 (15.300 MWh/a) 5.100 MWh/a Cold water _________________________________________ 8,7% Total electrical energy 60.600 MWh/a 35.750.000 kg CO2/a Electrical energy 2. Gas 71.200 MWh/a 31,7% Hot water2 (33.200 MWh/a) 36.900 MWh/a _________________________________________ Gas Total gas 108.100 MWh/a 21.600.000 kg CO2/a _________________ 40,7% Total 57.350.000 kg CO2/a Hot water 18,9% 141 kg CO2/unit1 Energy cold water = Electrical energy x 32 Energy hot water = Energy gas x 0.9© Dürr Systems GmbH, Green Paintshop, November 2011 - 17 -
  18. 18. CO2 Emission (Examples) kg/unit Yantai Norsom 291 kg/unit 300 268 kg/unit Changsha 250 208 kg/unit BMW 200 Shenyang 141 kg/unit 150 100 50 0 Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 18 -
  19. 19. VOC: Dürr’s Green Paintshop SolutionVOC abatement benchmark: 2,3 g/m2 2,3 g/m2 VOC Ecopure® TAR Ecopure® KPR VOC abatement systems 46,2 g/m2 VOC Others Oven Primer Ecopure® TARCOM Ecopure® RTO BC CC Interm. Oven Basis: Traditional process, 130 m2 paint surface, 31 jph;total VOC: 46,2 g/m2; Primer: 8,9 g/m2; BC: 9,8 g/m2, Interm. Oven: 1,1 g/m2; CC: 22,7 g/m2; Oven: 2,5 g/m2; others: 1,2g/m2© Dürr Systems GmbH, Green Paintshop, November 2011 - 19 -
  20. 20. VOC: Emission Examples g/m2 Norsom Abatement: oven 35 30,8 30 Nanjing Abatement: 25 oven 20 17,6 BMW Shenyang 15 Abatement: CC, oven Changchun 10 Abatement: primer, 7,3 BC,CC, oven 5 2,3 0 Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 20 -
  21. 21. Dürr’s Green Paintshop SolutionsWater consumption benchmark: 396,9 l/unit EcoFilter-Oil-UF EcoDryScrubber Air condition ing 17,1% PT EC 57,2% 25,7% EcoFilter-Oil-Sep EcoAirControl TH 10 0 % 4 0 °C 90% 80% 70% 60% 50% 3 0 °C 2 0 °C Ecopaint RoDip EcoHeatRecovery EcoIonEx© Dürr Systems GmbH, Green Paintshop, November 2011 - 21 -
  22. 22. Water Consumption (Examples) Dalian l/unit EcoAirControl TH EcoDryScrubber Ecopaint RoDip 1200 1065 l/unit Györ 1000 Norsom BMW Shenyang EcoIonEx EcoAirControl TH EcoAirControl TH EcoDryScrubber EcoFilter-Oil-UF EcoDryScrubber 800 Ecopaint RoDip EcoIonEx EcoAirControl TH 673 l/unit EcoHeatRecovery 595 l/unit EcoDryScrubber 600 Ecopaint RoDip 396,9 l/unit 400 200 0 Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 22 -
  23. 23. Water Consumption (Examples) l/unit 700 600 Shenyang 30 jph Shenyang Germany 60 jph Brazil 500 60 jph 420,9 l/unit 60 jph 396,9 l/unit 367 l/unit 400 349,5 l/unit 300 200 100 0 Dürr‘s „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 23 -
  24. 24. Dürr’s Green Paintshop SolutionsWaste water benchmark: 160 l/unit EcoDryScrubber EcoFilter-Oil-UF Air supply booths Air supply work decks 1,5% 0,3% EC PT EcoFilter-Oil-Sep 19,2% 79% Ecopaint RoDip EcoIonEx© Dürr Systems GmbH, Green Paintshop, November 2011 - 24 -
  25. 25. Dürr’s Green Paintshop SolutionsMaterial consumption benchmark: 118,5 €/unit others EcoBell3 PT Ecopaint RoDip Waxing EC CC Sealing LASD Primerless process, inside/outside BC automatic, BC: 70% metallic, CC: 2K Surface (EC): 90 m2 EcoLCC Surface (topcoat): 10 m2 Sealing: 100m EcoBell2 ICC UBC: 5m2 LASD: 1,5 m2 Prices paint material: EC: 10 €/kg BC: 12,3 €/kg CC: 10 €/kg© Dürr Systems GmbH, Green Paintshop, November 2011 - 25 -
  26. 26. Material Consumption (Examples) Traditional process €/unit (incl. primer), Interior manual, Traditional process ESTA machines (incl. primer), Interior manual Primerless 147 €/unit process; 150 132 €/unit Interior automatic, LCC 118,5 €/unit 100 50 0 Dürr „Green Paintshop“© Dürr Systems GmbH, Green Paintshop, November 2011 - 26 -
  27. 27. Green PaintshopMain factors of ecological sustainability© Dürr Systems GmbH, Green Paintshop, November 2011 - 27 -

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