Coil Coating Line Simulation An Introduction Webinar | April 2010 Graeme Peacock Peter Mitchell.
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Transcript of Coil Coating Line Simulation An Introduction Webinar | April 2010 Graeme Peacock Peter Mitchell.
Coil Coating Line SimulationAn IntroductionWebinar | April 2010
Graeme PeacockPeter Mitchell
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!
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
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
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
How to do coil coating line simulation• Using the ECCA coil coating model
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
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
8 Mb Of Free Hard
Disc Space
Inernet access
Requirements
Win NT, Windows 2000 or
laterExcel from
the MS Office 97 suite or
later
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
Running the model
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.
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.
EXIT MODULE
PAINTING PROCESS MODULE
PRETREATMENT MODULE
ENTRY MODULE
RAW MATERIAL RECEPTION
FINISHED PRODUCT STORAGE30
UNCOILER1
CLEANING/DEGREASING2
PRETREATMENT3
DRYING & COOLING4
PRIMER COATING (BACKER)5
CURING6
WET/DRY COOLING8
FINISH COATING9
CURING10
LAMINATING11
EMBOSSING16
WET/DRY COOLING17
PROTECTIVE FILM LAMINATOR18
SCRAP19
RECOIL20
WATER TREATMENT PLANT22
DEIONISATION23
SOFT WATER PRODUCTION21
SOLVENT LAUNDRY24
PAINT PREPARATIONSOLVENT CLEAN
25
OX
IDIS
ER
27
GA
S
CO
MB
US
TIO
N
26
COOLING SYSTEM29
COOLING TOWERS / CHILLER UNITS28
ECCA Coil Coating Line ModelProcess Composition
LAMINATING7
WET/DRY COOLING12
POWDER COATING13
CURING14
WET/DRY COOLING15
Processes Included In The Model
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
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
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
Main inputs (4)
• Curing Segment– Various curing techniques are provided:
• Convection • Induction• Infra red• Near infra red• UV
Global Variables input sheet
The Switchboard
Example worksheet: Recoil (proc 20)
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
UTILITIES COST PROFILE
0
50
100
150
200
250
Unc
oile
r
Cle
anin
g/D
egre
asin
g
Pre
trea
tmen
t
Dry
ing
& C
oolin
g
Prim
er C
oatin
g
Cur
ing
Lam
inat
ing
Wet
/Dry
coo
ling
Fin
ish
coat
ing
Cur
ing
Lam
inat
ing
Wet
/dry
coo
ling
Pow
der
coat
ing
Cur
ing
Wet
/dry
coo
ling
Em
boss
ing
Wet
/dry
coo
ling
Pro
tect
ive
film
Scr
ap
Rec
oile
r
Sof
t w
ater
pro
dn
Was
tew
ater
tre
atm
ent
DI
Wat
er s
uppl
y
Sol
vent
laun
dry
Pai
nt p
repn
Hea
t re
cove
ry
Sol
vent
Inc
iner
ator
Chi
ller
units
Coo
ling
syst
em
Sto
rage
(by P
rocess)
[€'0
00/y
r]
0
100
200
300
400
500
600
700
Cu
mu
lati
ve [
€'0
00/y
r]
Prim
er
Cu
ring
Cle
an
ing
Pre
treatm
en
tD
ryin
g
Coolin
g
Finish
Cu
ring
Coolin
g
Scra
p
Waste
wate
r Tre
atm
en
t
Solv
en
t Incin
era
tion
Coolin
g
Output reports (1)
WASTES COST PROFILE
0
5
10
15
20
25
30
35
Unc
oile
r
Cle
anin
g/D
egre
asin
g
Pre
trea
tmen
t
Dry
ing
& C
oolin
g
Prim
er C
oatin
g
Cur
ing
Lam
inat
ing
Wet
/Dry
coo
ling
Fin
ish
coat
ing
Cur
ing
Lam
inat
ing
Wet
/dry
coo
ling
Pow
der
coat
ing
Cur
ing
Wet
/dry
coo
ling
Em
boss
ing
Wet
/dry
coo
ling
Pro
tect
ive
film
Scr
ap
Rec
oile
r
Sof
t w
ater
pro
dn
Was
tew
ater
tre
atm
ent
DI
Wat
er s
uppl
y
Sol
vent
laun
dry
Pai
nt p
repn
Hea
t re
cove
ry
Sol
vent
Inc
iner
ator
Chi
ller
units
Coo
ling
syst
em
Sto
rage
(by P
rocess)
[€'0
00/y
r]
0
5
10
15
20
25
30
35
40
45
Cu
mu
lati
ve [
€'0
00/y
r]
Prim
er
Coatin
g
Finish
C
oatin
g
Waste
wate
r Tre
atm
en
t
Output reports (2)
ENERGY COST PROFILE
0
50
100
150
200
250
Uncoi
ler
Cle
anin
g/D
egre
asin
g
Pre
treat
ment
Dry
ing &
Coolin
g
Prim
er
Coating
Curing
Lam
inat
ing
Wet
/Dry
coolin
g
Fin
ish c
oating
Curing
Lam
inat
ing
Wet
/dry
coo
ling
Pow
der
coat
ing
Curing
Wet
/dry
coo
ling
Em
boss
ing
Wet
/dry
coo
ling
Pro
tective
film
Scra
p
Recoi
ler
Soft
wate
r pro
dn
Was
tew
ate
r tr
eatm
ent
DI
Wate
r su
pply
Solv
ent
laundr
y
Pain
t pr
epn
Heat
recove
ry
Solv
ent
Incin
era
tor
Chill
er
units
Coolin
g s
yst
em
Sto
rage
(by P
rocess)
[€'0
00/y
r]
0
100
200
300
400
500
600
700
Cu
mu
lati
ve [
€'0
00/y
r]
Cle
an
ing
Pre
treatm
en
t
Prim
er
Cu
ring
Finish
Cu
ring
Solv
en
t In
cinera
tion
Output reports (3)
Summary results
1. A comparison of a no-rinse and a rinsed
pretreatment with regard to energy, water use,
waste water and chemical requirements.
2. Savings related to reducing cleaner operating
temperatures and increasing the number of
subesequent rinses.
3. Paint costing exercise relating to curing techniques
Examples of using the model
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.
i. Alkaline oxide followed by 2 rinses and a chrome final rinse
ii. Chrome no-rinse applied with a chemcoater
0
50
100
150
200
250
Ch
emic
als
Was
te D
isp
osa
l
Was
te T
reat
men
t
En
erg
y,
Pre
trea
tmen
t
En
erg
y, W
aste
T
reat
men
t
Dry
ing
DI
Wat
er P
rod
Conventional Pretreatment
No Rinse
‘000€
No-rinse vs. rinsed pre-treatment
0
100
200
300
400
500
600
ConventionalPretreatment
No Rinse
DI Water Production
Drying
Energy cost wastetreatment
Energy costpretreatment
Waste Treatment
Waste Disposal
Chemicals
‘000€
40%
57%
25%
17%
12%
41%
No-rinse vs. rinsed pre-treatment
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.
– Cleaner sequence:-• 1 Preclean stage followed
by 1 rinse.• 2 Clean stages followed by
2 or 4 reverse cascaded rinses using DI water.
Temperature
Rins
ing
stag
es
55 °C 65 °C
2
4
42 4228 27
17 17
17 16
13 20
13 18
1717
17 17
1010
3 3
0
20
40
60
80
100
120'0
00€
DI Water Use
DI Water Production
Energy cost wastetreatment
Energy Cost Cleaner
Waste Treatment
Waste Disposal
550C 2 Rinses
650C2 Rinses
550C4 Rinses
650C4 Rinses
Cleaner stage:Effect of temperature and rinses
Temperature
Rins
ing
stag
es 55 °C 65 °C
2
4
Paint cost and curing techniques
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
Next Steps
• To buy the software or re-activate an existing license:– Email [email protected]
• Any problems with the software:– In the first instance, email
[email protected]• 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…