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 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…