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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
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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”
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Resource Efficiency - Introduction
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
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Resource Efficiency - Introduction
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*”
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Resource Efficiency - Introduction
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
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Resource Efficiency - Introduction
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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Resource Efficiency - Introduction
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 - Introduction
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
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Resource Efficiency - Introduction
Tool for Measuring Resource Efficiency: Life Cycle Assessment (LCA)
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� Resource Efficiency - Introduction
� Resource Efficiency - Status Quo
� Resource Efficiency - the Challenges
� Outlook
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Resource Efficiency in Car Body Painting - the Challenges
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)
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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
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Resource Efficiency - Status Quo
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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Resource Efficiency - Status Quo
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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Resource Efficiency - Status Quo
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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Resource Efficiency - Status Quo
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
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Resource Efficiency - Status Quo
Standard Automotive Painting Process - Optimization Step 2
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
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Resource Efficiency - Status Quo
Standard Automotive Painting Process - Optimization Step 3
heat recovery in spray booths + dry scrub + primerless
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New high-tech materials and processes improve resource efficiency
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Resource Efficiency - Status Quo
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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� Resource Efficiency - Introduction
� Resource Efficiency - Status Quo
� Resource Efficiency - the Challenges
� Outlook
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Resource Efficiency in Car Body Painting - the Challenges
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)
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Resource Efficiency - the Challenges
Standard Automotive Painting Process - further Optimization Possibilities
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Resource Efficiency - the Challenges
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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Resource Efficiency - the Challenges
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
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Resource Efficiency - the Challenges
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
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Resource Efficiency - the Challenges
Investment and Development of Operating Costs
Example: medium-sized painting plant
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� Resource Efficiency - Introduction
� Resource Efficiency - Status Quo
� Resource Efficiency - the Challenges
� Outlook
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Resource Efficiency in Car Body Painting - the Challenges
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
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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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