Coil Coating Line Simulation An Introduction Webinar | April 2010 Graeme Peacock Peter Mitchell

Webinar What to expect You should see this page and a toolbox to the right – If you cant hear me, check the audio settings in your toolbox – If you have a question, please type it in the question box I cant respond to everything immediately, but I will get to it before the end!

Coil Coating Line Simulation An 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 later Excel from the MS Office 97 suite or later

Accessing the model The software is downloaded from: – 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.

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

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

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

Cleaning Pretreatment Primer Curing Finish Curing Solvent Incineration 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

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

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 Rinsing stages 55 °C 65 °C 2 4

55 0 C 2 Rinses 65 0 C 2 Rinses 55 0 C 4 Rinses 65 0 C 4 Rinses Cleaner stage: Effect of temperature and rinses Temperature Rinsing stages 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: – Any problems with the software: – In the first instance, 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…