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

1. Integrated approach to energy optimisation in the
Integrated approach to energy optimisation in the
paint shop
from primary energy to consumer
Daniel Alonso
Daniel Alonso
Barcelona, 16.11.2011

2. Pressure to act
Corporate policy and strategy intensified to follow
sustainability & green footprint guidelines
CO2 reduction
Start
CO2 reduction
Trading
S ll
CO2 emissions & emissions trading
L i i d ti
Sell Buy
€ct/kWh
Low-emission production
Increasing energy costs
- limited resources
Coal
Natural gas
Petrolium
Uranium
Gas Price +110%
- rising energy demand
2040 2050 2070 2150
2000 2002 2004 2006 2008 2010 2012 2014 2016
Gas Price +110%

3. Current status from primary energy to secondary energy
final assembly
central power station
paintshop
Primary energy source Secondary energy source
press shop / body in white
Combined heat & power plant
Primary energy source
ƒ Gas
ƒ Coal
Secondary energy source
ƒ Hot water
ƒ Cold water
ƒ Oil ƒ Electricity
ƒ Compressed air
energy losses

4. Alternative concept with demand oriented energy generation
Direct integration of secondary energy Demand enables integration of renewable energies
l th l
ƒ solar thermal energy
ƒ photovoltaics
i t h
ƒ biomass
ƒ windpower
ƒ hydropower
ƒ block heat and power plant
paintshop
ƒ geothermal energy

5. Alternative concept with demand oriented energy generation
Example: air conditioning
100.000 m³/h air volume, required refrigeration capacity 900 kW.
1. Central cold water generation, chilling of fresh air
Cold water distribution 6/12°C all over the year independent from consumer
Cold water distribution 6/12 C all over the year independent from consumer.
Electrical power consumption: 404 kW
2. Local chilling unit via direct evaporation
Liquid refrigerant is the only required energy media, temperature individual depending on consumer.
Electrical power consumption: 284 kW
30% energy saving

6. Energy savings – EISENMANN approach and vision
Yesterday Today Near Future Vision
%
100
mption
in
%
80
100
gy
consum
60
Ener
20
40
0
20
conventional technology latest energy saving integration renewable future technologies
conventional technology latest energy saving
technologies
integration renewable
technologies
future technologies
conventional technologies energy optimsed technologies renewable technologies

7. EISENMANN Technology Portfolio for Energy Optimisation
Pre-Treatment/ ED
Electrostatic Scrubber
Renewable Energy
Pre-Treatment/ ED
E|SHUTTLE
Electrostatic Scrubber
E|SCRUB
Solar Thermal /
Cooling Concept
Thermal
Thermal
Oxidation
Thermal
Recuperation
Plant Process Control
E|MES
Skid conveyor
VarioLoc
Recuperation

8. Pretreatment / ED conveyor system E|SHUTTLE
ƒ Optimal corrosion protection
ƒ Optimal ED spread
Technical Benefits
ƒ No ED sanding
ƒ Skidless passage possible
ƒ Optimal layout possibilities
ƒ TCO reduction

9. Overspray separation system E|SCRUB
Technical Benefits*
ƒ Up to 95 % of the air can be recirculated
ƒ Energy consumption can be reduced by up to 75%
ƒ Noise level are up 10 dB (A) lower
P i l i i d d b 9 %
ƒ Particulate emissions are reduced by up to 97%
ƒ Lower consumption of chemicals
*compared to a conventional paint shop with wet scrubber system

10. Separation System E|SCRUB
Venturi Technology E|SCRUB Technology
fresh air (BC)
fresh air (CC)
Conventional Green
fresh air (CC)
i l t d i
23°C / 65 %
Fresh air
23°C / 65 %
recirculated air
23 C / 65 %
waste air
waste air (BC)
waste air (CC)

11. Exhaust air treatment EIComb and Bluemax burner
Bluemax
ƒ Lower electrical energy consumption
through optimized air guidance with
Technical Benefits E|Comb
Purified
gas
through optimized air guidance with
minimum loss of pressure
ƒ CO2 emissions reduced by approx. 15%
and lower NOx emissions
gas
ƒ Combustion temperature up to 20K lower
ƒ Optimum safety and maintenance
concept
Heat
exchanger
tubes
ƒ Gas consumption reduced by up to 15%
Heat exchanger tubes
ƒ Gas consumption reduced by up to 15%
Benefits Bluemax
exhaust
ƒ Savings on gas and power consumption
ƒ Clean gas values (C, CO, NOx) 20%
below german legal limits

12. Conveyor system VarioLoc
Technical Benefits
ƒ Enables skidless transportation of
car bodies
ƒ High reliability and flexability
ƒ Quick installation and start-up
ƒ Easy handover to skid conveyor
Cost Benefits
ƒ Lower CAPEX vs.
conventional skid-conveyor
y
ƒ Minimum maintenance costs -low
maintenance system

13. Plant Process Control Model E|MES
Evaluation of Energy and Consumption Values
ƒ Clear presentation in tables and diagrams
p g
ƒ Cumulative totals according to media
ƒ Comparison of consumption values
ƒ Long-term evaluation with different time profiles
C l ti ith d ti d t b d t
ƒ Correlation with production data e.g. body counter

14. Optimized building layout and ventilation
Main New Developments - Building
Shop ventilation and plant ventilation as ONE integrated design
Cascade ventilation from clean to less clean areas and from cooler areas to warmer areas. Ovens on higher
level to use natural convection. Heat recovery
y
Air conditioning only where required by the process
Less artificial lighting
Translucent wall panels for natural light.
Robots need no light
Robots need no light.
Buffer areas need no light.
G B ildi “
„Green Building“
LEED® standard, MINERGIE ® standard, Passivhaus standard.
Use of solar heat. Optimum insulation.

15. Technologies Comparation Conventional vs Energy saving
Conventional Paint Shop Energy Saving Paint Shop approach
Biggest Energy Consumption Now: Ovens
General Plant
Total: 2,62 GJ/u = 728 kWh/u
Biggest Energy Consumption: Spray Booths
Green Paint Shop
Total: less than 1,57 GJ/u = 435 kWh/u*
3%
Oven
30%
-40 % reduction of
energy consumption
3%
ƒ E|SHUTTLE – skidless in PT/ED
ƒ E|SCRUB with recirculating air
contribution
Booth
ƒ E|SCRUB with recirculating air
ƒ BLUEMAX
ƒ VarioLoc
ƒ E|MES
ƒ Optimized building
Building PT/ED
Repairs Applications
Material supply ƒ Optimized building
ƒ Improved oven insulation
ƒ Primerless process
Building PT/ED
Repairs Applications
Material supply

16. Technologies Comparation Conventional vs Energy saving
NOTE: more than 40% Energy saving by using the latest EISENMANN Technology; Not only the car manufacturer
looks on reducing the CO2, also their Partner EISENMANN

17. Energy savings – EISENMANN approach and vision
Yesterday Today Near Future Vision
%
100
mption
in
%
80
100
gy
consum
60
Ener
20
40
0
20
conventional technology latest energy saving integration renewable future technologies
conventional technology latest energy saving
technologies
integration renewable
technologies
future technologies
conventional technologies energy optimsed technologies renewable technologies

18. Solar thermal energy concept
There are many areas of application for the EISENMANN solar thermal energy concept in
a paint shop with significant effect on saving fossil fuels
Solar thermal modules
Heating
d /
dryer/oven
Hot
Heating
house/facility
Cold
water
Hot
water
Temperature
Cooling in
cooling
zones
Temperature
regulation
color mix
Heating pre-
treatment
Air conditioning
Spray booth

19. Product Description
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20. Example calculation for a solar paint shop integration
Pre treatment line (60 JPH) Sun irradiation* & Solar thermal plant
2.500 kW heat requirement
6.000 h/a (3 shifts)
= 15 000 MWh per annum
Solar thermal plant:
appr. 5.000 m²
Anticipated yield
appr. 600 KWh/m²a
solar earnings min.
= 15.000 MWh per annum
= 3.000 MWh/a
20%
100%
15.000 MWh
15.000 MWh
Solar
20 % Energy saving
in fossil fuels
80%
12.000 MWh
15.000 MWh
- 3.000 MWh
12.000 MWh
* Average irradiation in Germany (Stuttgart)
Example calculation for typical locations. Deviations possible

21. Example contracting model – energy price adjustment
0,60
0,70
0,80 Contracting period 15 years
Assumed energy price
development
Life cycle solar plant > 20 years
0 20
0,30
0,40
0,50
Possible solar energy price fixation
development
-
0,10
0,20
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031
k i
Äquivalenzpreis (herkömmliche Energie) Energiepreis Solarthermie
Benefits OEM during contracting Benefits OEM after contracting
market price Equivalent solar price
Price advantage start contracting: 10% – 15%
Yearly savings:
From approx. 15.000 € in the first year
Up to approx 200 000 € in 15th year
Cumulated savings: approx. 4-5 Mio €
Lifecycle power plant > 20 years
Up to approx. 200.000 € in 15th year
Cumulated savings:
approx. 1,2 Mio € over 15 years
Calculation basis:
y
Calculation basis:
2.000 m² collector field size, market energy price development 12%

22. Technologies Comparation using Solar Thermal Energy
NOTE: more than 40% Energy savings by using the latest EISENMANN Technology and 9% of them used with
renewable Energy by Solar Recuperation

23. The Vision of the Zero Emission Paint Shop
23

24. Contact
EISENMANN I i í S A
EISENMANN Ingeniería S.A.
Daniel Alonso
C/Berguedà 1 Parc de Negocis Mas Blau
C/Berguedà 1. Parc de Negocis Mas Blau
08820 El Prat de Llobregat (Barcelona)
E-Mail: daniel.alonso@eisenmann.com
Internet: www.eisenmann.com
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