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




Dr. Frederic de Molière


Barcelona, November 16-17, 2011
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-
Our Customers Go For Green


“The future will define ‘Premium’ by
the degree of sustainability.”
Dr. N. Reithofer, BMW



“Reduce CO2 in production by 40%
until 2020“
(VW, Mr. Klingler 9/11)



“Chinese car manufacturers to reduce
energy consumption for production by
yearly 5%”


© Dürr Systems GmbH, Green Paintshop, November 2011   -3-
Green Paintshop
Main factors of ecological sustainability




© Dürr Systems GmbH, Green Paintshop, November 2011   -4-
CPU Saving Potentials
Energy 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-
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-
Utility Calculation Tool
Calulation 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 power
Form 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-
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-
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-
Energy: Dürr’s Green Paintshop Solutions
Energy benchmark: 430 kWh per body (60 jph)
General Paintshop                                      Lean Layout     EcoEmos Energy       Ecopaint RoDip
Settings
  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 -
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 -
Energy Consumption: Sensitivity Analysis
Site (examples)




                                                                               - 59 kWh/unit
                                                                 Germany
                                                                                                    Shenyang


                                                                                                   - 59 kWh/unit
                                                                                               Yantai

                                                               - 97 kWh/unit




                                                      Brazil




© Dürr Systems GmbH, Green Paintshop, November 2011                                                                - 12 -
Energy consumption: Sensitivity Analysis
Production 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 -
Energy Consumption: Sensitivity Analysis
Working 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 -
Energy Consumption: Sensitivity Analysis
First 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 -
Energy Saving Potentials
Basis: 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 -
CO2: Dürr’s Green Paintshop Solution
CO2 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/unit




1
    Energy cold water = Electrical energy x 3
2
    Energy hot water = Energy gas x 0.9
© Dürr Systems GmbH, Green Paintshop, November 2011                                                                           - 17 -
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 -
VOC: Dürr’s Green Paintshop Solution
VOC 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 -
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 -
Dürr’s Green Paintshop Solutions
Water 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 -
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 -
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 -
Dürr’s Green Paintshop Solutions
Waste 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 -
Dürr’s Green Paintshop Solutions
Material 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 -
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 -
Green Paintshop
Main 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

  • 1. Paint and Final Assembly Systems Green Paintshop Status Quo and Future Perspectives Dr. Frederic de Molière Barcelona, November 16-17, 2011
  • 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. Our Customers Go For Green “The future will define ‘Premium’ by the degree of sustainability.” Dr. N. Reithofer, BMW “Reduce CO2 in production by 40% until 2020“ (VW, Mr. Klingler 9/11) “Chinese car manufacturers to reduce energy consumption for production by yearly 5%” © Dürr Systems GmbH, Green Paintshop, November 2011 -3-
  • 4. Green Paintshop Main factors of ecological sustainability © Dürr Systems GmbH, Green Paintshop, November 2011 -4-
  • 5. CPU Saving Potentials Energy 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. 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. Utility Calculation Tool Calulation 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 power Form 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. 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. 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. Energy: Dürr’s Green Paintshop Solutions Energy benchmark: 430 kWh per body (60 jph) General Paintshop Lean Layout EcoEmos Energy Ecopaint RoDip Settings 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. 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. Energy Consumption: Sensitivity Analysis Site (examples) - 59 kWh/unit Germany Shenyang - 59 kWh/unit Yantai - 97 kWh/unit Brazil © Dürr Systems GmbH, Green Paintshop, November 2011 - 12 -
  • 13. Energy consumption: Sensitivity Analysis Production 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. Energy Consumption: Sensitivity Analysis Working 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. Energy Consumption: Sensitivity Analysis First 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. Energy Saving Potentials Basis: 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. CO2: Dürr’s Green Paintshop Solution CO2 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/unit 1 Energy cold water = Electrical energy x 3 2 Energy hot water = Energy gas x 0.9 © Dürr Systems GmbH, Green Paintshop, November 2011 - 17 -
  • 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. VOC: Dürr’s Green Paintshop Solution VOC 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. 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. Dürr’s Green Paintshop Solutions Water 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. 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. 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. Dürr’s Green Paintshop Solutions Waste 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. Dürr’s Green Paintshop Solutions Material 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. 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. Green Paintshop Main factors of ecological sustainability © Dürr Systems GmbH, Green Paintshop, November 2011 - 27 -