Eco-Efficiency Analysis of Global Coating Processes - A Unique Approach - Strategies in Car Body Painting 2012

Transcription

1 Eco-Efficiency Analysis of Global Coating Processes - A Unique Approach - Strategies in Car Body Painting 2012 Dr. Hans Schumacher, Dürr Systems GmbH Dr. Alexander Haunschild, BASF Coatings GmbH

2 Table of Contents Evolution OEM-Coating paint processes Eco-Efficiency analysis: Method & scope Different paint processes & equipment technologies: Exemplary process study Paint processes Painting equipment Eco-Efficiency: Outlook 2

3 The Evolution of Paint Processes Shows, that the Combination of Process and Paint Offers the Best Eco-Efficiency Low Solid Basecoats Bell Medium + High Solid Basecoats Automation High Solid + waterborne Basecoats Bell/Bell Primerless Processes Full automation 1980s 1990s 2000s 2010 VOC Motivation VOC + Costs VOC+Energy+Costs Total Eco-Balance 3

4 Waterborne Basecoats Fulfill VOC - Regulation in Europe VOC g/m² Medium Solid High Solid High Solid Bell/Bell EU 2007 Brown field EU 2007 Green field Waterborne DE 2007 VOC regulations enforced introduction of waterborne coatings VOC is only one factor in Eco-Efficiency Analysis Eco-Efficiency Analysis provides holistic view on life-cycle 4

5 Ecological & Economical Targets FEWER EMISSIONS: Particulates, VOC, CO 2 Noise, Odors LESS MEDIA: Electricity, Gas, Water LESS MATERIAL: Paint, Chemicals HIGHER QUALITY / LESS COSTS Paintshop LESS WASTE LESS WASTE WATER HIGHER PRODUCTIVITY 5

6 Table of Contents Evolution OEM-Coating paint processes Eco-Efficiency analysis: Method & scope Different paint processes & equipment technologies: Exemplary process study Paint processes Painting equipment Eco-Efficiency: Outlook 6

7 Eco-Efficiency Analysis Is a Certified Method Strategic method developed by BASF to quantify criteria of sustainability Provision of a quantitative method to measure economical and ecological key data in a comparative system for products and processes Identification of most sustainable alternative in terms of a defined customer value; i.e. optimum in terms of environment and cost Third-party certified by the German Technical Monitoring Association (TŰV) and NSF International (P352)* *NSF: National Sanitation Foundation, Ann Arbor, Michigan, USA; NSF Protocol P352: Validation and Verification of Eco-Efficiency Analyses *UNCED: The United Nations Conference on Environment and Development, also known as the Rio Summit or Earth Summit was a major United Nations conference held in Rio de Janeiro from 3 June to 14 June UNCED 7

8 The Unique Project of DURR and BASF Contemplated the Whole Process Chain Production Coatings Production Basic Chemicals Dürr and BASF Coatings have access to all necessary data Phase Coatings Process Raw Materials and Energy Production Recycling Disposal from Cradle to Grave 8

9 Eco-Efficiency Analysis Quantifies all Environmental Effects Environmental Effects Ecological Fingerprint Environmental Burden Resource Consumption Energy Energy Consumption Emissions Land Use 1,00 0,50 Emissions low Tox-Potential Risk Potential Land Use Calculation of relative product position Resources 0,00 Toxicity Assessment of impact categories 1,0 Risk Alt.1 Alt.2 Alt.3 Alt.4 high Normalization Weighting Aggregation Normalization 9

10 Weighting Factors are Reflecting the Environmental Burden of all Ecological Areas Weighting Factor [%] Raw Material Resources Reserves Assessment [Years] [Mio t] [kg Ag eq.] Coal 119 4,1E+05 2,7E-04 Oil 46 1,8E+05 6,5E-04 Gas 63 1,6E+05 6,0E-04 Lignite 119 4,1E+05 2,7E-04 Uranium 37 2,3E+00 2,0E-01 NaCl ,8E+07 1,4E-05 Sulfur ,0E+05 2,6E-05 Phosphorus 122 1,8E+04 1,3E-03 Iron 70 7,1E+04 8,5E-04 Lime 500 1,8E+07 2,0E-05 Bauxite 197 2,5E+04 8,5E-04 Sand ,8E+07 1,4E-05 Copper 31 4,9E+02 1,5E-02 Titanium 120 7,3E+02 6,4E-03 Silver 13 2,7E-01 1,0E+00 VOC emissions have major effect on the environmental burden and are the source for the POCP Weighting factors are calculated on a impact base for the respective region Method also used by environmental agencies, such as UBA (Germany) Method also applied in other ecoefficiency models Gold 17 4,2E-02 2,2E+00 10

11 Eco-Efficiency Portfolio: Exemplary Presentation of Results Environmental Burden (norm.) 0,3 1,0 High Eco- Efficiency Alternative 1 Alternative 2 Alternative 3 Alternative 4 Evaluation of the Eco-Efficiency for production, use and recycling of one coated car based on all 11 weighted factors Cost-Per-Unit calculation Low Eco- Efficiency 1,7 1,7 1,0 Costs (norm.) 0,3 Not included in this study: Transportation costs E-Coat (seen as constant) Quality definitions Reparability and others 11

12 All Major OEM Coating Processes Have Been Analyzed Painting Equipment Bell-Bell, Bell int. Dry Scrubber EAP CC w/o Primer int. Bell-Bell, Bell int. Dry Scrubber EAP all booths Bell-Bell, Bell int. Dry Scrubber EAP CC Bell-Bell, Bell int. Dry Scrubber Bell-AIR, Bell int. Dry Scrubber EAP CC IP I IP I Primerless Primerless Primer 3-wet Medium Solid High Solid SB-CC WB-CC Gen. 1 Gen. 2 WB-BC 5a High Solid Bell-AIR, Bell int. Dry Scrubber Bell-AIR, Man int. Dry Scrubber EAP CC Bell-AIR, Bell int. Wet Scrubber Model based on some thousands different parameters 15 scenarios considered 2 different locations analyzed (Germany & China) Greenfield Plant in South Germany units/a mid-size car (11 m² exterior surface) starting from ED coated body IP: Integrated Process EAP: Exhaust Air Purification Paint Process 12

13 Table of Contents Evolution OEM-Coating paint processes Eco-Efficiency analysis: Method & scope Different paint processes & equipment technologies: Exemplary process study Paint processes Painting equipment Eco-Efficiency: Outlook 13

14 Comparison of Processes with Primer Conventional Process Primer Oven Basecoat Flash off Clearcoat Oven Processes using recirculated booth air Bell-Air application Waterborne Process Primer WB Basecoat WB Clearcoat SB-2K Solventborne MS Process Primer SB Basecoat SB Clearcoat SB-1K for MS Solventborne HS Process Primer HS Basecoat HS Clearcoat SB-1K for HS 14

15 Primary Energy Demand of Waterborne Process Energy Demand/Car [MJ] Total energy demand per car: MJ (677 kwh) 17% of energy demand generated by production of coatings 32% of energy demand needed for primer 15

16 Life Cycle Assessment Results: Processes Using Primer Oven Energy Demand 2,436 2,268 2,190 CO 2 global warming potential VOC Photochem. Ozone Creation Pot. 4,126 MJ/car kg CO2 /car g Ethylene eq. /car 1,413 2,871 WB MS HS WB MS HS WB MS HS Spray booth climatization for WB Intermediate dryer for WB VOC emissions from SB WB = Waterborne MS = Medium Solid HS = High Solid 16

17 Waterborne Process Is the most Ecological Standard Process environmental burden (norm.) 0,5 1,5 High Eco- Efficiency WB Solvent HS Solvent MS Considering all factors waterborne process is the most ecological High-solid process with less VOC compared to MS process 1,5 Low Ecoefficiency costs (norm.) 0,5 HS solventborne process with lowest cost 17

18 Compact Processes with Waterborne Basecoats Processes using recirculated booth air Bell-Bell application Conventional Process Primer Oven Basecoat Flash off Clearcoat Oven Integrated Process 1 st Layer 2 nd Layer Basecoat Basecoat w/ Primer Function Integrated Process I Bell/Bell application BC1, BC2, SB-2K CC Dryer phase for basecoats Integrated Process II Bell/Bell application BC1, BC2, SB-2K CC Basecoats wet-in-wet 18

19 Reduced Energy Demand, CO 2 - and VOC-Emissions by Primerless Processes Energy Demand 2,436 2,042 CO 2 global warming potential , VOC Photochem. Ozone Creation Pot. 1,413 1,268 1,268 MJ/car kg CO2 /car g Ethylene eq. /car WB IP I IP II WB IP I IP II WB IP I IP II Primer oven and booth Reduction of material Primer and BC WB = Waterborne IP I = Integrated Process I IP II = Integrated Process II 19

20 Gaining Eco-Efficiency with Waterborne Integrated Processes Gaining Eco-Efficiency with WB Integrated Processes environmental burden (norm.) 0,5 1,5 Low Ecoefficiency High Eco- Efficiency IP II IP I WB Primer Lower energy demand and CO 2 balance with IP II processes Different IP II processes (with one or two different basecoats) are similar Reduced costs with Integrated Processes 1,5 costs (norm.) 0,5 20

21 Short Processes with Solventborne Basecoats Processes using recirculated booth air Bell-Bell application Conventional Process Primer Oven Basecoat Flash off Clearcoat Oven 3-wet HS Process Primer Basecoat Clearcoat 21

22 Reduced Energy Demand, CO 2 - and VOC- Emissions by 3-wet HS Process Energy Demand 2,268 2,190 CO 2 global warming potential VOC Photochem. Ozone Creation Pot. 4,126 MJ/car 1, kg CO2 /car g Ethylene eq. /car 2,871 2,094 MS HS 3-wet HS MS HS 3-wet HS MS HS 3-wet HS Primer dryer High-solid content MS = Medium Solid HS = High Solid 22

23 Improved Eco-Efficiency for Solvent Processes by Less Process Steps environmental burden (norm.) 0,5 1,5 High Eco- Efficiency Solvent MS Solvent HS 3-Wet HS Reduced VOC with increased solid content (HSBC & Primer & CC) Reduced energy usage by less process steps (3-wet HS) Reduced costs with short SB process 1,5 Low Ecoefficiency costs (norm.) 0,5 Quality aspects are not included 23

24 Scope of Evaluation Can be Extended by Quality Factors 0,5 High Eco- Efficiency Schematic Presentation Dimensions of quality can be selected and weighted according the OEM s perspective 1,5 1,5 Low Ecoefficiency 0,5 high quality low 24

25 Table of Contents Evolution OEM-Coating paint processes Eco-Efficiency analysis: Method & scope Different paint processes & equipment technologies: Exemplary process study Paint processes Painting equipment Eco-Efficiency: Outlook 25

26 All Major OEM Coating Processes Have Been Analyzed Painting Equipment Bell-Bell, Bell int. Dry Scrubber EAP CC w/o Primer int. Bell-Bell, Bell int. Dry Scrubber EAP all booths Bell-Bell, Bell int. Dry Scrubber EAP CC Bell-Bell, Bell int. Dry Scrubber Bell-AIR, Bell int. Dry Scrubber EAP CC IP I IP I Primerless Primerless Primer WB-BC 5a Bell-AIR, Bell int. Dry Scrubber Bell-AIR, Man int. Dry Scrubber EAP CC Bell-AIR, Bell int. Wet Scrubber Model based on some thousands different parameters 15 scenarios considered 2 different locations analyzed (Germany & China) 3-wet Medium Solid High Solid SB-CC WB-CC Gen. 1 Gen. 2 High Solid Greenfield Plant in South Germany units/a mid-size car (11 m² exterior surface) starting from ED coated body IP: Integrated Process EAP: Exhaust Air Purification Paint Process 26

27 Comparison of the 5a Process Using Different Booth Concepts environmental burden (norm.) 0,5 Low Eco- Efficiency 1,5 1,5 costs (norm.) High Eco- Efficiency 0,5 Waterborne Dry Scrubber - Recirculated Air Waterborne Wet Scrubber - Fresh Air WB Dry Scrubber - and EAP Recirculated Air and Exhaus Air Purification Lower energy demand and CO 2 balance with Dry Scrubber booth Lower VOC emission due to Exhaust Air Purification (EAP) 27

28 Energy Efficiency Using New Booth Concepts Combined with Exhaust Air Purification Dry Scrubber overspray separation system: 60% less energy consumption in the spray booth VOC reduction by exhaust air purification up to 2,3 g/m² Total saving potential based on 60 million cars/year: 4 nuclear power plants kwh/unit USA 900 Hungary 790 China 740 China 650 Energy demand per car China 600 USA 470 China 430 Dürr paint shops recently implemented g/m EAP oven China 30.8 EAP oven China 17.6 EAP CC, oven China 7.3 VOC emission EAP Primer, BC,CC oven China 2.3 Dürr paint shops recently implemented 28

29 Comparison of 5a Process Using Different Application for Exteriors & Interiors 0,5 environmental burden (norm.) Low Eco- Efficiency 1,5 1,5 costs (norm.) High Eco- Efficiency 0,5 WB Bell-Air Air Manual Int. Interior with EAP CCspray booth WB Bell-Air with EAP CC-spray Bell Interior booth WB Bell-Bell Bell with Bell Interior EAP CCspray booth Lowest VOC emissions by highest application efficiency with the Bell³ painting process combined with low waste color change technique Higher cost efficiency due to automation 29

30 Paint Application for Highest Material Efficiency and Productivity Bell application with robots: CPU reduction due to highest transfer efficiency Color change technology for low material wastage Higher throughput due to higher First-Run-Rate and productivity CPU [ ] 150 Traditional process ESTA machines interior manual 147 /unit Net capacity [jph] Traditional process ESTA robots interior manual 132 /unit Compact process Fully automated Bell application /unit + 20% 0 Dürr paint shops recently implemented In Dürr paint shops recently implemented 30

31 Table of Contents Evolution OEM-Coating paint processes Eco-Efficiency analysis: Method & scope Different paint processes & equipment technologies: Exemplary process study Paint processes Painting equipment Eco-Efficiency: Outlook 31

32 Decision for New Paint & Process Technology Balance between Eco-Efficiency and individual requirements Frame Conditions Costs OEM Decision Process Ecology New painting equipment provides ecoefficient processes for all different paint processes Greenfield: Full automation with recirculated air & air purification Eco-efficient processes for water and solvent paints Compact coating processes are most eco-efficient Quality Brownfield revamps: Full automation Process equipment Compact coating processes are most eco-efficient 32

33 Decision for New Paint & Process Technology Balance between Eco-Efficiency and individual requirements New painting equipment provides ecoefficient processes for all different Costs paint processes Frame Conditions OEM Decision Process Ecology Each case needs to be reflected by the complete decision process of the OEM for the best paint process and equipment solution Quality 33

34 BASF and Dürr can provide per customer and region the most eco-efficient solution for all OEM-processes. The generally accepted holistic methodology delivers reliable and comparable results.