Coil Coating Line Simulation An Introduction

1. Coil Coating Line SimulationAn Introduction Webinar | April 2010 Graeme Peacock Peter Mitchell

2. WebinarWhat to expect You should see this page and a toolbox to the right If you can’t hear me, check the audio settings in your toolbox If you have a question, please type it in the question box I can’t respond to everything immediately, but I will get to it before the end!

3. Coil Coating Line SimulationAn Introduction Why coil coating line simulation? Introducing the ECCA coil coating line model Operating the ECCA coil coating line model Some examples

4. Why coil coating line simulation? Because a coil coating line is large, complicated and has many different inputs Because trials are expensive Because new technology is difficult, time-consuming and expensive to add to a line Because true cost calculations are very difficult

5. When might simulation be used? Assessing different configurations for a new line or for major upgrades e.g. moving to no-rinse pre-treatment or recuperative oxidiser Investigating the impact of minor changes e.g. changing solvent content of paint Optimising running conditions or product mix e.g. effect of speed on total cost or actual cost of different products Assessing the impact of cost changes on total cost e.g. the balance between different energy sources

6. How to do coil coating line simulation Using the ECCA coil coating model

7. The ECCA coil coating line model A model driven through Microsoft Excel Various input variables describe a coil coating line Typical values entered as default Instant calculations Cost by process Material use by process Environmental impact by process

8. Development of modelling software Developed by ECCA between 2002 and 2005 Directed by a group of ECCA members (TC12) Initially aimed at benchmarking against LCA, so includes environmental data Development partner Innoval Over 50 registered users

9. Requirements 8 Mb Of Free Hard Disc Space Win NT, Windows 2000 or later Inernet access Excel from the MS Office 97 suite or later

10. Accessing the model The software is downloaded from: www.innovaltec.com/modelinstall.html Requires validation code provided on request by ECCA If previously installed, annual access code provided free If a new user, invoiced at €2,000 for ECCA members, €3,500 for non-members per license 20% discount for multiple licenses

11. Running the model

12. Overall scope of the model (1) The user selects the processes that are required to form the virtual coil line. The model represents a steady state (time-averaged) situation. The model calculates specific variable costs, itemised by cleaner, pretreatment, electricity, gas, water, effluent treatment chemicals, coatings etc based on the total annual production of the coil line.

13. Overall scope of the model (2) Total material & energy use specified for each user selected process is calculated. Costs & material & energy uses are displayed for each of the user selected processes. A menu of 30 processes between the entry section & the exit recoiling section of a coil line is provided.

14. Processes Included In The Model

15. Main inputs (1) Entry & exit segment Strip parameters:- Substrate (Al, Steel), thickness, width, line speed Size of coils Number & size of pumps, motors & transportation systems Length of coil scrapped for each coil change

16. Main inputs (2) Pre-treatment segment Processes (Maximum):- 2 preclean stages, 6 counter current rinses 4 clean stages, 6 counter current rinses 4 rinsed pretreatments, 4 rinses, 2 post rinses 3 no-rinse pretreatments Heating, Water, Cleaner & Pretreatment Usage Waste output (oil, aluminium & pretreatment constituents) Water softening consumables Waste treatment chemicals (quantities & costs) Drier energy use & operational costs

17. Main inputs (3) Coating segment Processes (Maximum):- primers. backers, adhesives top coats including powder and UV cured coatings 2 hot laminating stages, one of which would allow the application of a top coat Wet paint thickness, % v/v solids, SG Required dry film thickness The model will allow the user to specify the frequency, duration & cost of stoppages related to paint changes

18. Main inputs (4) Curing Segment Various curing techniques are provided: Convection Induction Infra red Near infra red UV

19. Global Variables input sheet

20. The Switchboard

21. Example worksheet: Recoil (proc 20)

22. Main output data The model shows a series of pre-formatted reports that display: variable costs itemised by: cleaner, pretreatment, electricity, gas, water, effluent treatment chemicals, coatings total material use & effluent discharges for particular process sequences together with costs and material & energy uses total energy usage itemised by the main contributors

23. Output reports (1) Primer Curing Finish Curing Solvent Incineration Waste water Treatment Pretreatment Cooling Drying Cooling Scrap Cooling Cleaning

24. Output reports (2) Finish Coating Primer Coating Waste water Treatment

25. Output reports (3) Primer Curing Finish Curing Solvent Incineration Pretreatment Cleaning

26. Summary results

27. Examples of using the model 1. A comparison of a no-rinse and a rinsed pretreatment with regard to energy, water use, waste water and chemical requirements. Savings related to reducing cleaner operating temperatures and increasing the number of subesequent rinses. Paint costing exercise relating to curing techniques

28. No-rinse vs. rinsed pre-treatment Total & Component Cost Analysis for a rinsed & No-Rinse pretreatment Substrate: Steel. Coil feed: 60m/min, 1200mm wide, 0.6mm thick. Annual production: 110,000 tonnes. Alkaline oxide followed by 2 rinses and a chrome final rinse Chrome no-rinse applied with a chemcoater

29. No-rinse vs. rinsed pre-treatment Conventional Pretreatment No Rinse ‘000€ Drying Energy, Pretreatment Energy, Waste Treatment Chemicals DI Water Prod Waste Treatment Waste Disposal

30. No-rinse vs. rinsed pre-treatment ‘000€ 17% 12% 25% 41% 40% 57%

31. Cleaner stage:Effect of temperature and rinses Cost analysis of using 2 or 4 rinses at 55 °C or 65 °C Substrate: Steel. Coil feed: 60m/min, 1200mm wide, 0.6mm thick. Annual production: 110,000 tonnes. Rinsing criterion: 610. Temperature 65 °C 55 °C 2 Rinsing stages 4 • Cleaner sequence:- • 1 Preclean stage followed by 1 rinse. • 2 Clean stages followed by 2 or 4 reverse cascaded rinses using DI water.

32. Cleaner stage:Effect of temperature and rinses Temperature 65 °C 55 °C 2 Rinsing stages 4 550C 2 Rinses 650C2 Rinses 550C4 Rinses 650C4 Rinses

33. Paint cost and curing techniques

34. Conclusions Coil coating line modelling can benefit all coil coaters and suppliers to the industry Provides a low-cost, low-risk assessment tool Allows evaluation of different process sequences with regard to costs, material, water & energy usage and effluent discharge on your existing line Can be used in designing new lines or for minor changes to existing lines Provides data on: changed operational costs chemical consumptions waste production energy use

35. Next Steps To buy the software or re-activate an existing license: Email graeme.peacock@prepaintedmetal.eu Any problems with the software: In the first instance, email graeme.peacock@prepaintedmetal.eu Please complete the feedback which will be circulated If enough people want further help, we will run another webinar to fully demonstrate an example model Any questions – please type in the questions box…