CO 2 -Free Coil Coating Naive Dream or Realistic Scenario?

Transcription

1 Dr. Kai K.O. Bär, adphos Thermal Processing Technologies GmbH Andreas Geitner, adphos Thermal Processing Technologies GmbH Michael Schumann, adphos Thermal Processing Technologies GmbH CO 2 -Free Coil Coating Naive Dream or Realistic Scenario? Bruckmühler Strasse 27, Bruckmühl/Germany Phone: , Fax: , info@adphos.de

2 Introduction I 2010 (According to ECCA sustainability report) CO 2 -Emissions Direct emissions: (88.5 kg/t) Emissions due to electricity (indirect): (23.5 kg/t) Total emissions: 112 kg/t 2020 Zero-Emissions 0 700,000 t/a due to 6 Mio. t/a coil coated steel 2

3 Introduction II Zero CO 2 Emissons New, modified and/or solvent free coatings Modified and/or improved process technologies and/or modified coilcoating strategies Non-fossil electricity generation 3

4 Introduction III None of the required key milestones need priniciple new developments They are already available today 4

5 Introduction VI They need just Commercialization and/or Application in the coil coating business 5

6 New, Modified and/or Solvent Free Coatings (I) 2 in 1 water based primer, combined function of chemical pretreatment and primer function several coatings existing or close to market introduction some already verified in line trials (first commercial production 5 to 15 µm dry fim applicable conventional thermal process: drying at adphosnir thermal process: drying at 55 Final cure with finish coating drying / curing 6

7 New, Modified and/or Solvent Free Coatings (II) High solid content coatings epoxy-based (finish) coatings 65 % up to 75 % solid content first coatings existing and into market introduced, verified already in line trials up to 25(!) µm dry film applicable verified, also with adphosnir curing conventional thermal process: 230 at 20 s adphosnir thermal process: 215 at 5 s Has been verified already in combination with 2 in 1 primer 7

8 New, Modified and/or Solvent Free Coatings (III) Acrylic based finish coatings and/or finish coatings with lower PMT curing 180 (adphos NIR ) to 210 (conventional) coatings existing in the market verified already in production conventional thermal process: 210 at 20 s adphosnir thermal process: 180 at 5 s Applicable today, but more expensive 8

9 New, Modified and/or Solvent Free Coatings (IV) Fully water based primer and/or finish coatings Existing in commercial coil coating production (90 % of New Zealand coil coatings are water based!) Partially in commercial production at BlueScope Steel facilities (e.g.vietnam, Thailand) Long term outdoor verification (> 5 years) of adphosnir cured pilot production samples conventional thermal process: 235 at 25 s adphosnir thermal process: 220 at 5 s Applicable today, but higher energy costs with hot air ovens 9

10 New, Modified and/or Solvent Free Coatings (V) Powder coatings Partially existing in commercial coil coating production But limitations today due to - low speed capable powder application devices - high coating thickness requirements resulting form particle size Applicable today, but limited productivity 10

11 New, Modified and/or Solvent Free Coatings (VI) UV/EB-Curing coatings Partially existing in niche coil coating production Applicable in principle, but extrem increased coating costs (factor 3 5!) 11

12 Modified/Improved Process Technologies and Strategies (I) Todays conventional coil coating process (CCL) 12

13 Modified/Improved Process Technologies and Strategies (II) Comparison between conventional CCL and fully on demand BAT based CCL 13

14 Modified/Improved Process Technologies and Strategies (III) HDG/EGL with inline Paintsection (IPS) Vertical horizontal 14

15 Modified/Improved Process Technologies and Strategies (IV) HDG with 2 in 1 in a conventional vertical configuration HDG with 2 in 1 but adphosnir -based drying: in a vertical configuration 15

16 Modified/Improved Process Technologies and Strategies (V) HDG with 2 in 1 but adphosnir -based drying in a horizontal configuration 16

17 Modified/Improved Process Technologies and Strategies (VI) Compact coil coating line (C 3 L) as patented by adphos 17

18 Modified/Improved Process Technologies and Strategies (VII) Paint process in slitting line Paint process in roll forming line Paint process in other vertical down stream production line 18

19 Non-Fossil Electricity Generation (I) CO 2 Emission of Different Electricity Generation Technologies Fossil electrical power generation Brown coal: 1 kg CO 2 per kwh electricity Stone coal: 0.5 kg 0.7 kg CO 2 per kwh electricity Oil fired: 0.5 kg CO 2 per kwh electricity Gas fired (high efficiency): (0.3 kg) 0.5 kg CO 2 per kwh electricity Non-fossil electrical power generation 1) Photo voltaics: 0.12 kg CO 2 per kwh electricity Bio gas: 0.06 kg CO 2 per kwh electricity Nuclear power: 0.04 kg CO 2 per kwh electricity Wind energy: 0.03 kg CO 2 per kwh electricity Hydro power: kg CO 2 per kwh electricity 1) Below CO 2 emission result from the manufacturing/exploration energy requirements 19

20 CO 2 Emissions Resulting from Energy Mix of Electricity Generation Norway < kg per kwh electricity Scandinavia < 0.10 kg per kwh electricity France 0.15 kg per kwh electricity Average Data for Europe 0.28 kg per kwh electricity (evaluated by ECCA) USA 0.35 kg per kwh electricity Germany 0.45 kg per kwh electricity Italy 0.6 kg per kwh electricity India, China 0.8 kg per kwh electricity Australia 1.0 kg per kwh electricity 20

21 Evaluation of Potential CO 2 Emission Savings (I): Modified Coating 2 in 1 Primer High solid finish coating 65 % 75 % Lower PMT acrylic primer/finish coating 2 in 1 and high solid finish coating 65 % 75 % Fully water based primer/finish coatings CO 2 reduction due to./. 33 %./. 33 %./. 42 % -./. 60 %./. 70 %./. 100 % reduced solvents 1) CO 2 reduction due to energy savings - Gas ovens:./. 40 % + 33 % + 42 %./. 15 % + 60 % + 70 % % - Conv. electrical thermal Systems:./. 40 % - -./. 15 %./. 40 %./. 40 % - - adphosnir systems:./. 50 %./. 10 %./. 10 %./. 30 %./. 60 %./. 60 %./. 10 % 1) Compared to todays average data according ECCA Sustainability Report

22 Evaluation of Potential CO 2 Emission Savings (II): BAT Application Todays average performance ECCA Fully on demand CCL (adphosnir ) IPS 2 in 1 HDG and C 3 L With high solid coating Fully on IPS 2 in 1 HDG Demand and C 3 L Total energy consumption - Gas: - Electricity: 420 kwh/t 337 kwh/t 83 kwh/t 140 kwh/t 2 kwh/t 138 kwh/t 132 kwh/t 2 kwh/t 130 kwh/t 81 kwh/t 1 kwh/t 80 kwh/t kwh/t 0.5 kwh/t 126 kwh/t kwh/t 0.5 kwh/t 115 kwh/t 73.5 kwh/t 0.5 kwh/t 73 kwh/t Direct CO 2 emissions - Gas: - Solvents: Indirect CO 2 emissions Total CO 2 emissions 58.3 kg/t 30.2 kg/t 0.4 kg/t 23.5 kg/t 0.4 kg/t 23.5 kg/t 0.2 kg/t 6.4 kg/t 0.1 kg/t < 14 kg/t 0.1 kg/t < 14 kg/t 0.1 kg/t < 4 kg/t 23.5 kg/t 39 kg/t 36.8 kg/t 22.7 kg/t 35.7 kg/t 32.6 kg/t 20.7 kg/t kg/t 62.9 kg/t 60.7 kg/t 29.3 kg/t 49.8 kg/t 46.7 kg/t 21.2 kg/t CO 2 savings -./. 44 %./. 46 %./. 74 %./. 56 %./. 58 %./. 81 % 22

23 Todays CO 2 -Emissions Average and Capability Todays average engery consumption ECCA New IPS with adphosnir Improved savings Potential todays IPS with 2 in 1 Improvements savings 2020 potential IPS based - Gas: - Electricity : 337 kwh/t 83 kwh/t < 2.0 kwh/t 130 kwh/t./ % + 56 % < 0.5 kwh/t 75 kwh/t./ %./. 10 % 0 60kWh/t Direct CO 2 - Gas: - Solvents: 58.3 kg/t 30.2 kg/t 0.4 kg/t 23.5 kg/t./ %./ % < 0.1 kg/t 6.4 kg/t./ %./. 79 % 0 0 Indirect CO kg/t 36.8 kg/t + 56 % 21.2 kg/t./. 9 % 0 (<< 3 kg/t) Total CO kg/t 60.7 kg/t./. 46 % 27.7 kg/t./ % 0 (<< 3 kg/t) Water usage > 720 1,290 kg/t < 10 kg/t./ % < 5 kg/t./ % < 5 kg/t Solvent usage 9.5 kg/t 7.0 kg/t./. 5 % < 2.0 kg/t./. 79 % 0 (< 0.1 kg/t) 23

24 Cost Savings in Addition to Ecological Benefits Due to reduced energy - gas: 0.02 /kwh 0.20 /kg - electricity: /kwh Due to reduced coating costs - 5 /kg Due to reduced water treatment - >/ ~ 5 /m 3 Due to higher net production hours % productivity increase Due to lower scrap % (todays average 3.4 %) Due to lower investment / operator costs 24

25 Cost Savings Potential with adphosnir (IPS) 25

26 Summary / Conclusions CO 2 free coil coating production until 2020 is possible, if Solvent free coatings are applied Modified/changed process technologies and coating production strategies are adapted and Non-fossil electricity production is established No principle new developments are here for necessary; all required systems and technologies Do exist and/or Are close to market introduction and/or Are planned already More than 90 % reduction in total CO 2 emissions can be already justified today! Beside the ecological benefit, High energy savings and High conversion cost earnings are resulting too 26

27 Green washing strategies with gas driven thermal process systems nor gas or other fossil electricity production will fail the goal and resulting conversion costs are significant higher 27

28 Yes, we could But: Biggest risk / barrier is principle required change of coil coating habits 28