Daniel Alonso - Integrated approach to energy optimization in the paint shop from primary energy to consumer

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Integrated approach to energy optimization in the paint shop from primary energy to consumer

By Daniel Alonso

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Daniel Alonso - Integrated approach to energy optimization in the paint shop from primary energy to consumer

  1. 1. Integrated approach to energy optimisation in thepaint shopfrom primary energy to consumerDaniel AlonsoBarcelona, 16.11.2011
  2. 2. Pressure to actCorporate policy and strategy intensified to followsustainability & green footprint guidelines Start CO2 reduction Trading Sell S ll Buy CO2 emissions & emissions trading Low-emission production L i i d ti €ct/kWh Uranium Petrolium Natural gas CoalIncreasing energy costs- limited resources Gas Price +110%- rising energy demand 2000 2002 2004 2006 2008 2010 2012 2014 2016 2040 2050 2070 2150
  3. 3. Current status from primary energy to secondary energy final assembly paintshop central power station Combined heat & power plant press shop / body in white Primary energy source Secondary energy source Gas Hot water Coal Cold water Oil Electricity Compressed air energy losses
  4. 4. Alternative concept with demand oriented energy generationDirect integration of secondary energy Demand enables integration of renewable energies solar th l thermal energy l photovoltaics biomass windpower block heat and power plant hydropower paintshop i t h geothermal energy
  5. 5. Alternative concept with demand oriented energy generationExample: air conditioning100.000 m³/h air volume, required refrigeration capacity 900 kW.1. Central cold water generation, chilling of fresh airCold water distribution 6/12°C all over the year independent from consumer 6/12 C consumer.Electrical power consumption: 404 kW2. Local chilling unit via direct evaporationLiquid refrigerant is the only required energy media, temperature individual depending on consumer.Electrical power consumption: 284 kW 30% energy saving
  6. 6. Energy savings – EISENMANN approach and vision Yesterday Today Near Future Vision mption in % 100 80Energy consum 60 40 20 0 conventional technology latest energy saving integration renewable future technologies technologies technologies conventional technologies energy optimsed technologies renewable technologies
  7. 7. EISENMANN Technology Portfolio for Energy Optimisation Pre-Treatment/ ED E|SHUTTLE Renewable Energy Electrostatic Scrubber Solar Thermal / Cooling Concept E|SCRUB Thermal Plant Process Control Oxidation E|MES Thermal Recuperation Skid conveyor VarioLoc
  8. 8. Pretreatment / ED conveyor system E|SHUTTLETechnical Benefits Optimal corrosion protection Optimal ED spread No ED sanding Skidless passage possible Optimal layout possibilities TCO reduction
  9. 9. Overspray separation system E|SCRUBTechnical Benefits* Up to 95 % of the air can be recirculated Energy consumption can be reduced by up to 75% Noise level are up 10 dB (A) lower Particulate emissions are reduced b up to 9 % P i l i i d d by 97% Lower consumption of chemicals *compared to a conventional paint shop with wet scrubber system
  10. 10. Separation System E|SCRUB Venturi Technology E|SCRUB Technology Conventional Green fresh air (BC) Fresh air fresh air (CC) 23°C / 65 % 23 C 23°C / 65 % recirculated air i l t d i waste air waste air (BC) waste air (CC)
  11. 11. Exhaust air treatment EIComb and Bluemax burnerTechnical Benefits E|Comb Bluemax Lower electrical energy consumption through optimized air guidance with minimum loss of pressure CO2 emissions reduced by approx. 15% and lower NOx emissions Purified gas Combustion temperature up to 20K lower Optimum safety and maintenance concept Heat exchanger tubesHeat exchanger tubes Gas consumption reduced by up to 15%Benefits Bluemax Savings on gas and power consumption Clean gas values (C, CO, NOx) 20% exhaust below german legal limits
  12. 12. Conveyor system VarioLocTechnical Benefits Enables skidless transportation of car bodies High reliability and flexability Quick installation and start-up Easy handover to skid conveyorCost Benefits Lower CAPEX vs. y conventional skid-conveyor Minimum maintenance costs -low maintenance system
  13. 13. Plant Process Control Model E|MES Evaluation of Energy and Consumption Values Clear presentation in tables and diagrams p g Cumulative totals according to media Comparison of consumption values Long-term evaluation with different time profiles Correlation with production d t e.g. b d counter C l ti ith d ti data body t
  14. 14. Optimized building layout and ventilation Main New Developments - BuildingShop ventilation and plant ventilation as ONE integrated designCascade ventilation from clean to less clean areas and from cooler areas to warmer areas. Ovens on higher ylevel to use natural convection. Heat recoveryAir conditioning only where required by the processLess artificial lightingTranslucent wall panels for natural light.Robots need no light light.Buffer areas need no light.„Green Building“ G B ildi “LEED® standard, MINERGIE ® standard, Passivhaus standard.Use of solar heat. Optimum insulation.
  15. 15. Technologies Comparation Conventional vs Energy saving Conventional Paint Shop Energy Saving Paint Shop approach Biggest Energy Consumption: Spray Booths Biggest Energy Consumption Now: Ovens General Plant Green Paint Shop Total: 2,62 GJ/u = 728 kWh/u Total: less than 1,57 GJ/u = 435 kWh/u* 3% Oven 30% -40 % reduction of energy consumption 3% contribution Booth E|SHUTTLE – skidless in PT/ED E|SCRUB with recirculating air BLUEMAX VarioLoc E|MES Repairs Material supply Building PT/ED Applications Optimized building Improved oven insulation Primerless process
  16. 16. Technologies Comparation Conventional vs Energy savingNOTE: more than 40% Energy saving by using the latest EISENMANN Technology; Not only the car manufacturerlooks on reducing the CO2, also their Partner EISENMANN
  17. 17. Energy savings – EISENMANN approach and vision Yesterday Today Near Future Vision mption in % 100 80Energy consum 60 40 20 0 conventional technology latest energy saving integration renewable future technologies technologies technologies conventional technologies energy optimsed technologies renewable technologies
  18. 18. Solar thermal energy conceptThere are many areas of application for the EISENMANN solar thermal energy concept ina paint shop with significant effect on saving fossil fuels Solar thermal modules Heating dryer/oven d / Heating house/facility Hot Cold water water Temperature Cooling in regulation cooling color mix Heating pre- zones treatment Air conditioning Spray booth
  19. 19. Product Description 19
  20. 20. Example calculation for a solar paint shop integration Pre treatment line (60 JPH) Sun irradiation* & Solar thermal plant Anticipated yield 2.500 kW heat requirement Solar thermal plant: appr. 600 KWh/m²a 6.000 h/a (3 shifts) appr. 5.000 m² solar earnings min. = 15.000 15 000 MWh per annum = 3.000 MWh/a Solar 20% 100% 15.000 MWh 15.000 MWh - 3.000 MWh 20 % Energy saving 80% 12.000 MWh in fossil fuels 12.000 MWh * Average irradiation in Germany (Stuttgart) Example calculation for typical locations. Deviations possible
  21. 21. Example contracting model – energy price adjustment Life cycle solar plant > 20 years 0,80 Contracting period 15 years 0,70 Assumed energy price 0,60 development 0,50 0,40 Possible solar energy price fixation 0,30 0,20 0 20 0,10 - 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 market price k i Äquivalenzpreis (herkömmliche Energie) Equivalent solar price Energiepreis Solarthermie Benefits OEM during contracting Benefits OEM after contractingPrice advantage start contracting: 10% – 15% Cumulated savings: approx. 4-5 Mio €Yearly savings: Lifecycle power plant > 20 years From approx. 15.000 € in the first year Up to approx approx. 200.000 200 000 € in 15th yearCumulated savings: approx. 1,2 Mio € over 15 years y Calculation basis: 2.000 m² collector field size, market energy price development 12%
  22. 22. Technologies Comparation using Solar Thermal EnergyNOTE: more than 40% Energy savings by using the latest EISENMANN Technology and 9% of them used withrenewable Energy by Solar Recuperation
  23. 23. The Vision of the Zero Emission Paint Shop 23
  24. 24. ContactEISENMANN I Ingeniería S A i í S.A.Daniel AlonsoC/Berguedà 1. Parc de Negocis Mas Blau 108820 El Prat de Llobregat (Barcelona)E-Mail: daniel.alonso@eisenmann.comInternet: www.eisenmann.com ◙ 24

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