Dr. Kai K. O. Bär, adphos Thermal Processing GmbH Andreas Geitner, adphos Thermal Processing GmbH Strategies for cutting production costs in coating lines (Extended Version) Bruckmühler Strasse 27, 83052 Bruckmühl/Germany Phone: +49 8061 395-0, Fax: +49 8061 395 395, info@adphos.de www.adphos.de Strategies for cutting production costs in coating lines Thermal Processing GmbH 2 1
Actual Circumstances in the Crisis What has Changed? Demand destruction (reduced orders 30 70 % down) Reduced production accordingly or even more Mostly up again Still partially existing Reduced operation hours Reduced number of shifts Reduced operation days (complete shut downs) Partially recovered Reduced order size (smaller batch size per order) Existing Reduced stock production Existing 3 But this Requests Shorter process runs Higher flexibility (non optimised production scenarios) More discontinuity (more interruptions, more changes) This also remains today! Shorter reaction/delivery And even lowest prices! 4 2
Most Strip Process Require Multiple Heating (1) Process NIR-Application Existing Solution Benefits with NIR Hot Mill Edge heating Induction Defined and precise controlled local heating Pickling Preheating strip Not established due to space limits and thermal efficiency Scale microcracking and preheated strip lead to increased pickling efficiency Rinse water drying Dry lube or passivation treatment Hot air drying (partially with additional afterwards cooling) Not established due to given space limits Extreme compact and high drying efficiency, mostly no afterwards cooling required Extreme compact and high added value to the coil process Annealing Preheating strip (booster before stationary heat treatment) Complete strip annealing process Induction Resistant or gas ovens Defined and precise coil width adjustable heating high process efficiency and application in hazardous atmosphere Extreme compact due to fast strip preheating, extreme dynamic process operation due to law inertial heat mass, instantaneous power adaptation to actual strip geometry required process profile. 5 Most Strip Process Require Multiple Heating (2) Process NIR-Application Existing Solution Benefits with NIR Metal coating lines Preheating strip/chemical (Electro-Galv., Hotdip cleaning section Galv., Sn-coating ) Preheating strip (booster) before Galv. pot in HDG Not established due to space limits Induction Rinse water drying after chemical cleaning Passivation drylube treatment Heating metal coated strip Induction (galvanealing) Preheated strip leads to increased cleaning efficiency, adjustable power to actual strip geometry Extreme compact, therefore smaller space requirement, adjustable power to actual strip geometry See pickling See picklinig Extreme compact, therefore smaller space requirement, adjustable power to actual strip geometry Inline organic painting Induction Defined and precise controlled curing process, extreme compact, only possibility for colour coating on demand process. Tremendous added value (high cost saving to CCL process) 6 3
Most Strip Process Require Multiple Heating (3) Process NIR-Application Existing Solution Benefits with NIR Colour coating line Drying process for chemcoating Gas convection, IR, Induction Extreme compact, significant lower strip temperature avoids mostly afterward cooling high process efficiency Curing of primer, backer, finish coating Gas convection IR Ultra fast curing, precise defined process, high process efficiency, extreme compact only on demand coating possibility Steel service center and other vertical follow on coil process (e.g. roll forming, slitting processes) Inline organic painting MiCConD Not established due to space limits and not possible on demand coating See Inline organic painting in metal coating line 7 Heating/cooling steps are mandatory (driv ing factors) for process lines: Dimensioning (sizing) Performance (throughput, production scenario) Energy requirements Operation needs Reliability Cost of production and resulting/remaining profit! 8 4
Examples to be Presented NIR-Booster to increase capacity in existing coating lines NIR for preheatment primer in galvanising line energy saving, added value, cost reduction NIR-Technology for cost reduction in coil coating line Combined galvanising and colour coating line MiCConD A long term dream becomes reality 9 NIR-Booster to Increase Capacity in Existing Coating Lines 10 5
What does a Booster? Why a Booster would be needed? 11 Application Fields of Booster Increase of production higher speed but check also VOC-, quench-, other systems higher gauge but check also quench constant speed during gauge color changes Dynamic operation/no dummy coil increase of production, due to higher net production hours no dummy coil operation no reduced speed Improve of quality (critical coatings) production increase, due to now possible higher process speed Application of conventional paints for bake hardening coil product higher curing temperature paints can be applied, without thermal hardening 12 6
Booster for Speed Compensation 13 Booster for Different Strip Gauges 14 7
What is Special with NIR Booster? All other technologies (IR, induction) are limited to strip temperatures of 100 C!! paint still wet and therefore high blister risk in following zone 1 of gas oven strip temperature in Booster to high blistering Required air ventilation requests significant changes in solvent extraction system 15 Why NIR is Special? Only NIR allows strip fast preheating up to 150 C (up to 170 C) without blistering following zone 1 in hot air section can be applied with high temperature and high airflow rate Only NIR fully compatible with hot air system existing extraction system can remain and even LEL controlled operation is possible!! 16 8
Function Concept of NIR Pre Booster NIR oven with no skin building evaporation of most solvents 25 C 160 C 200 C 220 C 240 C 240 C High speed air flow required for sufficient efficiency at these temperatures Therefore most solvents must already have been evaporated. Otherwise air stream would damage the surface Conventional Curing only evaporation of remaining solvents 17 Function Concept of NIR Post-Booster Post Booster - process limitations expected due to skin creation in existing oven (e.g. in case of large coating thickness) 120 C 25 C 70 C 160 C 180 C 240 C Conventional Drying solvents evaporated with early skin building NIR oven for curing only small solvent amounts acceptable due to existing skin barriers 18 9
Space for Booster Integration (1) Space Options Size reduction of coater room Removal of first oven zone 19 Space for Booster Integration (2) Space Options 20 10
Typical Layout of Booster Configuration 21 Example: Technical Specification and Major Requirements Substrate: Different galvanised qualities Width: t.b.d. to 1,260 mm Thickness: t.b.d. Max. production speed: 200 m/min Paint types: Polyesters, PU, PVDF, Inlet temperature at Booster: 60 C Required PMT after Booster: 160 C ( T : 100 K) Max. solvent content (assuming total 22 µm dry): 320 kg/h Reference coil (for power dimensioning): Available space in front of oven entry section: 0.42 mm x 940 mm x 200 m/min 6,700 mm 22 11
NIR Booster Layout (1) 23 Photograph of Booster 24 12
Proposed Air Ventilation and Interface to Existing Oven 25 Further Potential Booster Application Fields Vertical Booster in front of annealing oven Preheating strip before cleaning section increase speed without extension of cleaning zone improved cleaning section performance (higher strip temperature) very attractive energy balance, due to on demand power adjustment (especially with heat recovery for bath heating and rinse water drying) 26 13
Conclusions Intrinsic production increase 15 % - 30 % Allows small batch runs due to on demand operation Even for demand destruction, strong cost saver due to net production increase no standby requirements better quality Replacement requires very low down time less than a week!! 27 Replacement of Complete Gas Oven Can be also very economical Estimated payback of actual projects India less than 8 months Saudi Arabia I less than 6 months Saudi Arabia II less than 20 months Italy less than 13 months 28 14
NIR for Pretreatment Primer in Galvanizing Line - Energy Saving, Added Value, Cost Reduction 29 Todays Typical Solution in Post Treatment Section Vertical roll coater Application of no rinse passivation Vertical gas oven Drying passivation coating 70 C 80 C Vertical air cooling Cooling strip < 60 C before entering exit accumulation 30 15
Potential Optimization Replacement of gas oven to NIR Required drying temperature max 60 C reduced T: 25 C 60 C = 35 K, conventional 25 K 20 K 55 K Reduced heating energy: - 37 % Existing air cooling system becomes obsolete No cooling required Reduced energy: - 50 % of conventional heating 31 Additional Benefits with NIR Large space saving NIR-Dryer max. 1/3 1/5 of gas dryer allows integration of second coater for flexible fast coating changes NIR-Dryer enables to dry cromfree passivation systems with no reduced performance NIR-Dryer allows new coatings application 32 16
Application Examples (3a) Passivation treatment (vertical) Application Examples (3b) Passivation Treatment (vertical) 34 17
Pre-Treatment Primer in Galvanizing Line Actually new coating developments Combination of chemcoating pretreatment and organic primer Water based products organic primer Pre-painted coil product for further downstream processing Required conventional process: Drying / Heating: 90 C 120 C Required NIR-Drying-Process: 60 C (max. 70 C) 35 NIR-Pretreatment Primer Process Added value for existing galvanizing line Partial change of paint production (no need for CCL operation) Additional market!! 36 18
NIR-Technology for Cost Reduction in Coil Coating Line (IMS-Integrated Integrated Modular Solutions) 37 Thermal Processes in CCL s Heating of cleaning bath (chemical cleaning) Rinse water drying (and eventual cooling) of strip Chemcoating drying (and eventual cooling) depending on dryer technology Drying/curing of primer coating Strip cooling after 1 st curing process Drying/curing of finish coating Strip cooling after 2 nd curing process VOC-destruction of solvents Eventual preheating of air for solvent exhaust Infrastructure/auxiliaries Coater room air conditioning (heating/cooling) Waste water treatment Power cabinets cooling Other 3 rd processes (drying of strip after tension leveler) 38 19
Integrated Modular Solution (IMS) Power optimization of thermal processes and optimized combination of relevant process steps based on newest generation of NIR-based dryer/oven configuration 39 Integrated Modular Solution Design Aspects NIR curing Ov ens: Standard paints require 10 % lower T ( 215 C) Primer Top Coat No preheating/no standby Preheating air by heat recov ery of clean gas from RTO-sy stem Cooling power cabinets by inlet air for emitter cooling Heat recov ery form emitter cooling for preheating air unit for air nozzle after water quench Heat recov ery for preheating cleaning bath of chemical cleaning section 40 20
Integrated Modular Solution Design Aspects In optimized combination with VOC- Destruction Sy stem: RTO Heat/cooling source recovery for coater room air conditioning LEL-controlled air flow control for solv ent exhaust Fully autotherm operation during all coating production scenarios (no gas consumption, during standby only for longterm stops and start up) 41 Integrated Modular Solution Design Aspects NIR-chemcoating dryer: Chemcoating require ½ T (PMT 55 C) No preheating/standby No/less strip cooling (max. 50 %) heat recov ery for high performance air nozzle for rinse water dry ing (for chemical cleaning section) 42 21
Principle Layout of IMS RTO 43 Integrated Modular Solutions Energy Consumption Considerations (1) Total specific energy consumption (including all required infrastructure/auxiliar y equipments) Equipment/Process Chemcoating dryer including cooling systems and all pumps, blowers, etc. Primer and finish coating oven including all blowers, pumps, etc. W aterquenches and air nozzles after primer/finish ovens including all blowers, pumps, etc. RTO system including preheating air for solvent exhaust in ovens, ventilation in coater rooms, all blowers, etc. Total energy consumption Specific Energy consumption 8 12 kw h/t 100 120 kw h/t 5 kw h/t < 10 kw h/t + 5 kw h/t gas (only required for start up at longterm stops) < 130 150 kw h/t 44 22
Integrated Modular Solutions Energy Consumption Considerations (2) Equipment/Process Cooling of power cabinets Cooling down (up to T = - 20 K) or heating up (up to T = + 20 K) of ambient air for coater rooms Preheating cleaning bath of chemical cleaning section Drying rinse water of chemical cleaning section Potential heat recovery hot air (200 C) from VOC destruction system (at 8 kg/t solvent content) from water cooling cycles of NIR-dryers/ovens from hot air ( 120 C) from emitter cooling Specific Energy Consumption Included Included Included and < 1 kw h/t for pump Included and < 1 kw h/t for blower./. 25 kw h/t ( 3 t of steam)./. 25 kw h/t ( hot water at 70 80 C)./. 5 kw h/t (for other drying processes e.g. tension leveler) 45 Comparison of Energy Consumption (1) (Reference Coil: 0.5 mm x 1,300 mm at 80 m/min (24.5 t/h)) Process Standard Induction NIR-IMS Chemical cleaning Heat: Pumps: 280 kw (28 Nm³/h) 20 kw (el.) 280 kw (28 Nm 3 /h) 20 kw (el.) Heat recovery 20 kw (el.) Rinse water dryer Heat: Blower: Air cooling: Blower: 250 kw (25 Nm 3 /h) 25 kw (el.) 250 kw (25 Nm 3 /h) 50 kw (el.) 250 kw (25 Nm 3 /h) 25 kw (el.) 250 kw (25 Nm 3 /h) 50 kw (el.) 25 kw (el.) Not required Chemcoating Heat: Blower: Air cooling: Blowers, Pumps: 400 kw (40 Nm 3 /h) 50 kw (el.) 100 kw (el.) 280 kw (el.) 25 kw (el.) 100 kw (el.) 255 kw (el.) 15 kw (el.) 10 kw (el.) 46 23
Comparison of Energy Consumption (2) (Reference Coil: 0.5 mm x 1,300 mm at 80 m/min (24.5 t/h)) Process Standard Induction NIR-IMS Primer/Finish + VOC Heat: Blower: Water quenches, pumps: Air dryers 250 kw (25 Nm 3 /h) 25 kw (el.) 250 kw (25 Nm 3 /h) 50 kw (el.) 250 kw (25 Nm 3 /h) 25 kw (el.) 250 kw (25 Nm 3 /h) 50 kw (el.) 25 kw (el.) Not required Total Gas: Electricity: 523 Nm 3 /h 1,010 kwh/h 103 Nm 3 /h 37.5 kwh/h ------ 2,950 3,350 kwh/h Specific Consumption Gas: Electricity: 21 Nm 3 /t 41.2 kwh/t 4.2 Nm 3 /t 151.6 kwh/t ----- 120 136 kwh/t 47 Comparison Complete Energy Consumption (Reference Case: 24.5 t/h) Energy Standard Induction NIR-IMS Total Gas: Electricity: 523 Nm 3 /h 1,010 kw 103 Nm 3 /h 37.5 kw ------ 2,950 kw 3,350 kw Av erage production (18 t/h 75 % ) 500 Nm 3 /h 1,000 kwt/h 95 Nm 3 /h 3,350 kwh/h ----- 2,250 kwh/h 2,550 kwh/h 6,000 production hours 1,500 standby + preheating 3 10 6 Nm 3 /a 6 10 6 kwh/a 1.125 10 6 Nm 3 /a 1.5 10 6 kwh/a 0.57 10 6 Nm 3 /a 20.1 10 6 kwh/a 0.10 10 6 Nm 3 /a 0.12 10 6 kwh/a 13.5 10 6 kwh/a 15.3 10 6 kwh/a 0.05 10 6 kwh/a Total annual consumption Gas: Electricity: 4.125 10 6 Nm 3 /a 7.5 10 6 kwh/a 0.67 10 6 Nm 3 /a 20.22 10 6 kwh/a 13.55 10 6 kwh/a 15.35 10 6 kwh/a Annual Production (108.000 t) Gas: Electricity: 38.2 Nm 3 /t 69.4 kwh/t 6.2 Nm 3 /t 187 kwh/t (1.2 Nm 3 /t) 125.5 kwh/t 142 kwh/t 48 24
Resulting Benefit from Above Energy consumption of NIR based thermal process section Primer + Finish oven: 100 (dark) 120 (for 9002) kwh/t Chemcoating dryer: 8 12 kwh/t Cooling systems (water quenches), RTO based < 20 kwh/t VOC-destruction system, infrastructure/auxiliar y components (e.g. blowers, pumps, ) Total consumption: 130 150 kwh/t (electr.) + 5 max. 10 kwh/t (gas) but substantial heat recovery potential for 3 rd processes (up to 80 kwh/t possible). Energy consumption only during paint production (+ 2 5 minutes before/after painting, due to safety/reliability requirements). 49 Additional Optimization Potential Paint Increased absorption characteristic (e.g. NIR absorbers) Reduced solvent content (higher solid content, H 2 O based) Reduced curing temperature (T 180 C) Further improved process efficiency, higher process reliability (less risk of scrap) and lower CO 2 -emissions 50 25
Resulting IMS Benefits NIR-based Integrated Modular Solution ensures: High performance painted coil product at least as good as conv entional processed Full coil coating on demand production High sy stems reliability and low maintenance effort Today s lowest energy consumption for complete coil coating process Today s lowest energy operation costs for complete coil coating process Today s lowest conv ersion costs Today s most applicable curing technology, even under limited space conditions, when all other technologies can not be applied Today s most experienced fast curing technology in running production lines 51 But Every Application is Special, Therefore customized application and onsite conditions optimized design configurations needed! adphos provides NIR-based integrated modular solutions alike LEGO standardized system component design/layout solution for optimized thermal coil treatment and coil coating. 52 26
Large Variety of Systems for Optimized Adaptation Strip pass vertical or horizontal Special space constraints (extreme compact designs available) Heat recovery from chemcoating dryer (e.g. air cooled for rinse water drying; water cooled for chemical bath preheating) Low, intermediate or high speed applications Air ventilation/voc-process configuration depending on product mix, production scenario, energy media costs, regional climate, heat recovery requirements Optimized infrastructure, auxiliary or other 3 rd processes can strongly reduce overall energy consumption as well as environmental emissions But, not complicated, keep it smart and simple 53 Energy efficient and environmental friendly CCL operation processes are given with NIR - based Integral Modular Solutions 54 27
Conclusion We have also NIR! NIR is just another IR System! Is that true? 55 Combined Galvanizing and Color Coating Line 56 28
Long Time Dispute Inline Painting Sections vs. Independent Stand Alone Color Coating Line 57 Inline Paint Section: PRO s 58 29
Inline Paint Section Mandatory Requirement Start-Stop operation (instantaneous start up scheduled/unschedul ed restarts) Dynamic operation (flexible acceleration/deceleration of process) Flexible process adaptation to a actual coil geometry Flexible process adaptation to actual strip product (quality) Defined and reproducible process operation parameters 59 Inline Paint Section The Musts Get in high performance rate (98 %) typical of a HDG line Get high and stable quality rate on production Flexibility on any thickness and width variation of the strip Flexibility on any speed variation 60 30
Curing Requirements for Finish Coatings 2 4 4 6 NIR-oven (patented by adphos) UV-oven (special UV-curing paints required) 8 10 13 16 Induction oven Elect. Infrared oven (e.g. BGK, Solaronics,...) 16 20 High (catalytic) gas oven (flotation typ) Gas convection oven 20 25 (catenary typ) 61 62 31
Sketch of the IPS Design for CGL 3 WATER QUENCH (FINISH) WATER QUENCH (PRIMER) NIR OVEN SEGMENTS 1-4 (PRIMER OVEN) NIR OVEN SEGMENTS 1-4 (FINISH OVEN) NIR OVEN (CHEM OVEN) PRIMER AND BACK COATER ROOMS TO EXIT LOOPER FINISH COATER ROOM FROM TENSION LEVELLER 63 3D-View of IPS from Operator Side WATER QUENCH (FINISH) WATER QUENCH (PRIMER) NIR OVEN SEGMENTS 1-4 (PRIMER OVEN) NIR OVEN SEGMENTS 1-4 (FINISH OVEN) RTO NIR OVEN (CHEM OVEN) PRIMER AND BACK COATER ROOMS FINISH COATER ROOM TO EXIT LOOPER FROM TENSION LEVELLER 64 32
Benefits by a Combined Line Investment costs reduction: - 25 % Operative production costs reduction: - 30/40 % Scraped material rate reduction: - 50/60 % Logistic operative rate (handling, stocking) reduction: - 50 % 65 MiCConD A long Dream becomes Reality Micro Colour Coating on Demand 66 33
MiCConD Another small size / compact CCL?? 67 Conventional CCL 68 34
Compact Line Downsized Conventional CCL 69 NO 70 35
MiCConD Micro Color Coating on Demand Is not just a compact CCL MiCConD A new concept for organic coil coating 71 Current Situation Large and complex CCL s with high production output Slow, non-continuous mini CCL s with high investment costs, low productivity and similar operation efforts like standard CCL`s So today s philosophy: When pre-painted coil, do it professionally! 72 36
Typical Requirements Small tonnage coated coil badges ( 100m) Sampling and/or pilotizing of new products Dev elopment /Verification of new coating processes with respect of production scale Start-up production of new products, customized solutions New Opportunities Coating on Demand Decentralized, customized, just in time, on customer site coating On site, Inline Coating in coil forming processes and /or business 73 All starts with Coating on Demand 74 37
Coating on Demand Process Requirements Instantaneous coating processes, without long(er) time requiring start-up procedures Instantaneous Start/Stop without scrap nor pre/after works, preparation requirements Dynamic coating processes (during variable production speed) without dummy coil /standby operation Small size batches Simple facility configuration Small / compact layout 75 Goal of MiCConD Compact layout for smallest and small size production rates (< 1 t/h 10 t/h) Flexible but high performance coatings application (esp. Finish coatings) Low investment costs, low operation costs but state of the arte system technologies Installation within max. 2 weeks! No dummy coil No preheating No special coating developments are need! 76 38
Principal MiCConD - Process Coil Feed Coating Application Drying/Curing Strip Cooling Further Strip Processing Powder Wet Coatings (solvent/water based) NIR Air Cooler, Cooling Rolls, Quench Most Simple MiCConD Unwind Roll Coater NIR Cooling Rewind 5 m depending on speed 10 15 m depending on speed 77 Major Application Fields (1) Today s coil coater/coil processing companies Production of small size batches, nitch applications and coated product sampling Decentralized - order driv en onsite deliv ery Serv ice Centers Just in time on order deliv ery (esp. color, coil geometries, volume) esp. Integration in slitting and/or cut to length lines 78 39
Major Application Fields (2) Vertical coil processing Integration in roll forming Integration in roll to sheet process lines esp. replacement of today s component coating applications Emerging markets for coil coating Coating manufacturer or further coating process developments Sampling production for new products Process/feasibility verification for new process/measurement components 79 (Required) Pre Products for MiCConD Process Pretreated coils in CGL Preprimed coils treatment primer in post-treatment section in CGL Clear or cleaned coil substrate as required (galv, stainless steel, aluminium, ) Twice operation of primer/finish applications in MiCConD Finish coating application in MiCConD Integration of chemcoating + twice operation of primer/finish in MiCConD 80 40
Typical System Charactaristics Substrate: Geometry : Thickness: Width: Production speed: Different (pretreated) galv, stainless steel, alu qualities 0.1 mm 1.2 mm (others on request) 300 mm 1,500 mm (others on request) 5 m/min 35 m/min (others on request) Production rate: St: 0.5 t/h 10 t/h Alu: 0.1 t/h 3.5 t/h Annual production capacity: 2,500 t/a (1 shift) 60,000 t/a (3 shift) Depending on coil geometry 81 Typical System Layout (1) 1 Coat/Slitted Procecss 82 41
Typical System Layout (2) 1 Coat/Slitted Procecss 83 Typical System Layout (3) Coil to Coil 2 Coat/2 Bake 84 42
Schematical Layout of MiCConD-Rollforming Process 85 MiCConD Process Performance Continuous dynamic coating operation 3 m/min (< 5 m scrap) < 1 % of production (even batch sizes of 100 m < 5 %) Minimum batch size of 20 m Case of operation (max. 2 Persons) 86 43
Special Benefits of MiCConD (1) Low preparation effor (max. 15 30 min) Min. scrap ( 5 m coil loss) Smallest space requirements ( 5 m complete coating process; 15 m complete stand-alone solution) Dynamic coating operation from start to stop line Extreme flexible process/product as well as production scenarios No manual process operation necessary (fully atomized and self controlled) manual coil feed in/out manual coater preparation manual coater cleaning / color change High process efficiency and state of the arte and green technology 87 Special Benefits of MiCConD (2) Low maintenance / service requirements Clean ambient conditions and low infrastructual requirements (electricity, air, eventual water, gas for VOC) Low investment costs < 8 month from order to production Pre-acceptance at adphos with coil coating operation Installation at customer within max. 2 weeks later 88 44
Not only a Vision! MiCConD Micro Color Coating on Demand Coil coating in a size of a living room 89 Costs MiCConD based solutions provide Break even at 2.500 5.000 t/a Proven! 90 45
Conclusion MiCConD is not a competition to existing standard CCL`s MiCConD is not a product but a modular, flexible concept to allow new coil coating processes! 91 adphos MiCConD summit at February 01 st / 02 nd 2011 We will present first public view of MiCConD see invitations for details! 92 46
Resumee Applicable for all thermal processes in galvanizing / coating lines Green field applications as well as upgrades in existing lines NIR provides large cost reductions, energy savings and CO² reductions NIR Today s technology for your success 93 Thank you for your attention! 94 47