resource efficiency in car body painting -the challenges · lcs life cycle simulation gmbh,...

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Resource Efficiency in Car Body Painting

- the Challenges

Herausforderung Ressourceneffizienz in der Karosserielackierung

Dr. Matthias Harsch, Julian Maruschke, Judith Schnaiter

LCS Life Cycle Simulation GmbH, Backnang, Germany

www.lcslcs.de

Strategies in Car Body Painting 2012

Automotive Circle International, 28 - 29 June 2012, Berlin, Germany

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� Resource Efficiency - Introduction

� Resource Efficiency - Status Quo

� Resource Efficiency - the Challenges

� Outlook

2

Resource Efficiency in Car Body Painting - the Challenges

Overview

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Resource Efficiency - Introduction

Viewing Angle

Pressefoto BASF Coatings GmbH

view into

details

overall view

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� In 2040 the population will

reach a record high (8,1 billion)

� Climate change will persist

(global warming, decline in

species diversity, reduction of

the ice in the Arctic, etc.)

� Focus on short-term purposes

prevent wise decisions for long-

term wellbeing

� “Business as usual is not an

option if we want our grand-

children to live in a sustainable

and equitable planet”

4


Central Statement of the Club of Rome

Source: 2052: A Global Forecast for the Next Forty Years, 2012

The Limits of Growth: The 30-Year Update, 2004

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� The state of the planet:

biodiversity has declined

globally, human demand on the

planet exceed supply, water

scarcity

� Rising greenhouse gas

emissions and global

temperature have significant

impacts on biodiversity, water,

ecosystems, food and human

wellbeing in general

� „Do Nothing“ scenario is not an

alternative. WWF proposes to

manage, govern and share

natural capital within the earth‘s

natural boundaries

5


WWF Living Planet Report 2012

Source: www.wwf.de/fileadmin/fm-wwf/Publikationen-PDF/WWF_LPR_2012.pdf

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scarce

resources

demographic

change

climate change;

energy consumption

fresh water

shortage

megatrends

of

sustainability

complexity

dynamic

Knowledge management of increasing “dynaxity*”

6


Challenges for a Sustainable Future

*Dynaxity = Dynamics + Complexity

Source: megatrends of sustainability, Bundesministerium für Umwelt, Berlin, 2008

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production

sites

worldwide

technologies

(state-of-the-art,

innovations)

work time

model

LCS

life cycle

models

technology

strengths, weak

points, potentials

economy

limits of profit-

ability, cost drivers

ecology

resources,

emissions

be

nc

hm

ark

Understand (transparency) – rearrange – evaluate – implement

7


Knowledge Management - Part of LCS Services

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renewable resources

non-renewable resources

React to permanently changing boundary conditions

technosphere ecosphere

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Interaction between Technosphere and Ecosphere

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Source: European Environment Agency (EEA), 2011

No standardised definition of resource efficiency within the EU

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Resource Efficiency in Europe

RE

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production

use

recycling

preparation

Life Cycle Assessment (ISO standards 14040 & 14044):

The measure of resource efficiency

goal/

scope definition

inventory

analysis

impact

assessment

LCA framework

resources

emissions

to environment

renewable

resources

carbon cycle

10


Tool for Measuring Resource Efficiency: Life Cycle Assessment (LCA)

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� Outlook

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Overview

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0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Production Use phase

Pri

ma

ry e

ne

rgy d

em

an

d [

GJ/c

ar]

Resource efficiency in production is important

0%

10%

20%

30%

40%

50%

60%

70%

80%

Pri

mary

en

erg

y d

em

an

d [

MJ/h

]

150.000 up to 200.000 km

Graphic does not show energy requirement per time

LCS estimations: total production: 240 h/car; operation: 3.333 h/car (60 km/h, 200.000 km)

12

Resource Efficiency - Status Quo

Life Cycle Perspective

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paint production

en

erg

y s

up

ply

tran

sp

ort

an

d

recycli

ng

pro

cesses

resins solvents pigments fillers additives

automotive

paint shop

13


Standard Automotive Painting Process - System Boundary for Comparison

car body

paintedcar body

preparation of resources

production of basic chemicals

production of chemical intermediates

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e-coat oven

180°C, car body

e-coat sanding

body repair

e-coat

dip painting

20.000 m3/h

pretreatment

10.000 m3/h

seam

sealing

60.000 m3/h

underbody

sealing

60.000 m3/h

sealer oven

130°C, car body

primer

spray booth

300.000 m3/h

body shop

base coat

spray booth

400.000 m3/h

flash off

80°C, car body

primer sanding

primer oven

160°C

clear coat

spray booth

300.000 m3/h

top coat oven

140°C, car body

inspection,

polishing

repair

preparation

spot repair

cavity wax

applicationassembly shop

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Standard Automotive Painting Process - Overview Process Steps

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0

100

200

300

400

500

600pretreatment

e-coat (dip)

e-coat oven

sb seam sealing

seam sealing oven

sb primer

primer oven

sb BC

flash-off BC

sb CC

top coat oven

cavity sealingP

rim

ary

en

ery

in

MJ p

er

car

bo

dy

Process

Material

100%

Primary energy = total of heating values of used renewable

and non renewable energy resources for

energy supply and material production

Total energy: 5,5 GJ or 130 kg crude oil equivalents

*sb = spray booth, BC = base coat, CC = clear coat

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Standard Automotive Painting Process - Starting Point

*

* * *

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0

100

200

300

400

500

600pretreatment

e-coat (dip)

e-coat oven

sb seam sealing

seam sealing oven

sb primer

primer oven

sb BC

flash-off BC

sb CC

top coat oven

cavity sealingP

rim

ary

en

ery

in

MJ p

er

car

bo

dy

Process

Material

91%

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Standard Automotive Painting Process - Optimization Step 1

heat recovery in spray booths

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84%

0

100

200

300

400

500

600pretreatment

e-coat (dip)

e-coat oven

sb seam sealing

seam sealing oven

sb primer

primer oven

sb BC

flash-off BC

sb CC

top coat oven

cavity sealingP

rim

ary

en

ery

in

MJ p

er

car

bo

dy

Process

Material

17



heat recovery in spray booths + dry scrub

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72%

0

100

200

300

400

500

600pretreatment

e-coat (dip)

e-coat oven

sb seam sealing

seam sealing oven

sb primer

primer oven

sb BC

flash-off BC

sb CC

top coat oven

cavity sealingP

rim

ary

en

ery

in

MJ p

er

car

bo

dy

Process

Material

18



heat recovery in spray booths + dry scrub + primerless

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New high-tech materials and processes improve resource efficiency

19


Standard Automotive Painting Process - Summary Optimization Steps

- 26 % process

resource efficiency

- 2 % material

resource efficiency

72 %

process

28 %

material

100 % primary energy

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� Outlook

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Overview

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Requirement: quality and competitiveness

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Resource Efficiency - the Challenges

Further Optimization Steps - Selection

status quo

process optimization

changing boundary conditions

life cycle perspective

concept corrosion protection & paint

filmsconcept coil coating

process & material optimization

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0

100

200

300

400

500

600pretreatment

e-coat (dip)

e-coat oven

sb seam sealing

seam sealing oven

sb primer

primer oven

sb BC

flash-off BC

sb CC

top coat oven

cavity sealingP

rim

ary

en

ery

in

MJ p

er

car

bo

dy

Process

Materialpressure drop

(air flows)

new technologies

here not evaluated

ovens

(thermal energy)

22


Standard Automotive Painting Process - further Optimization Possibilities

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On Going Public Research Activities - 2 BMBF Projects

� new paint shop concepts

� new process technology

� new 3D UV concepts

(materials & processes)

ENSIKOM

http://www.ipa.fraunhofer.de/Green_Carbody_Technologies.1053.0.html

www.r-zwei-innovation.de/de/673.php

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Changing boundary conditions require technology modifications

2000 2010 2020 2030 2040 2050

Rela

tive e

nerg

y c

osts

conventional powerplants

renewable energysystems

break even

~2027

Source: Arbeitsgemeinschaft DLR, IWES, IFNE, 2011

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Changing Boundary Conditions - Example Electricity Costs in Germany

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0

2

4

6

8

10

12

Standard power mix

DE 2011

Renewable power

mix DE 2011

Thermal energy (gas)

EU

Pri

ma

ry e

ne

rgy

in

MJ

pe

r k

Wh renew.

fossil

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

Standard power mix

DE 2011

Renewable power

mix DE 2011

Thermal energy

(gas) EU

CO

2-e

qu

iva

len

ts in

kg

pe

r k

Wh

Possible technology modification in paint shops,

e.g. electricity for heat generation

25


Changing Boundary Conditions - Example Ecoprofiles for Energy Supply

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Plant operation time in years

po

ten

tia

l

4 millions investment

2 millions/a operating costs

0

10

20

30

40

50

60

0 5 10 15

To

tal c

os

ts in

mill. E

UR

O

44 millions in 20 years

Long plant operation time � consider the life cycle costs

26


Investment and Development of Operating Costs

Example: medium-sized painting plant

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� Outlook

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Overview

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Loop of decreasing costs and improving quality will run out on paint

shop level, added values of innovations have to be appreciated on

life cycle level

Astandard

life cycle

life cycle

after innovationA

B

B

C

C

D

D

+

-

∑standard LC

∑LC innovation

+

-

∆ added

value

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Resource Efficiency - Outlook

Life Cycle Perspective Required for Evaluation of further Optimization Potentials

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3,0 million tons crude oil equivalents per year

53 oil tanker á 56,000 tons net load per year

6,1 million tons CO2 equivalents per year

50,7 bn. km at 120g CO2 per km

250.000 cars with 200.000 km mileage

boundary conditions: complete world wide automobile production (2011: 65,4 millions)

savings: difference standard to optimized and renewable energy

Resource Efficiency - Outlook

Life Cycle Optimization Potential - Estimation

100% 72% 50% 33%

change to 40%

renewable energyusing existing potentials

using new

materials & processes

29

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LCS Life Cycle Simulation GmbH

www.lcslcs.de

Contact persons:

Dr.-Ing. Matthias Harsch

Managing director

tel.: +49 7191 9035 835

email: [email protected]

Dipl.-Ing. Julian Maruschke

Project leader

tel.: +49 7191 2104 298

email: [email protected]

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resource efficiency in car body painting -the challenges · lcs life cycle simulation gmbh,...

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