FAW_VW_Chengdu_EcoDryScrubber

1、涂裝及總裝系統(tǒng)涂裝及總裝系統(tǒng)Paint and Final Assembly SystemsEcoDryScrubber The Green Paint SeparationOctober 29th, 2009- 2 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009議事日程議事日程 Agenda EcoDryScrubber 綠色綠色解決方案解決方案 The Green Solution EcoDryScrubber 動畫演示動畫演示 Movie EcoDryScrubber 技術(shù)技術(shù) Technology EcoDryScrub

2、ber 與濕式分離方式對比與濕式分離方式對比 vs. Wet separation EcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings EcoDryScrubber 業(yè)績業(yè)績 References- 3 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009五個關(guān)鍵原理五個關(guān)鍵原理 5 Key Elements of EcoDryScrubber靈活安裝靈活安裝 Installation Flexibility 充分發(fā)揮該系統(tǒng)的靈活性 full installation f

3、lexibility of the system 全自動的分離過程全自動的分離過程 Fully Automated Separation Process 廢料被自動清除Saturated precoat materialis removed automatically簡易的分離系統(tǒng)簡易的分離系統(tǒng) Simplified Separation System 過濾器和石灰石組成 Consist only of filters and lime stone再生濾芯再生濾芯 Regenerative Filter Elements 潔凈氣體的濃度 0.1mg/m3 Clean gas concentra

4、tion 15.000小時) Long filter replacement-cycle (lifetime proven 15.000 hours) 維修維修 Maintenance - 10% 不需要水處理不粘附噴涂物No water for overspray separation 不需要凝聚化學(xué)品 No usage of coagulation chemicals 不需要漆渣處理 No disposal of sludge 空調(diào)用水最大可減少95 % Up to 95 % reduced water for air conditioning 材料材料 Material 1% Maint

5、enance 維護(hù)維護(hù)Material 材料材料MaintenancePersonellInvest equipmentEnergyMaterialInvest buildingMaintenancePersonellInvest equipmentEnergyMaterialInvest building12%61%3%EcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings- 29 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009Total CPU Saved 總總CP

6、U節(jié)約節(jié)約*歐洲涂裝車間， 165.000 u/年 Paintshop in Europe, 165.000 u/year, 投資成本，德國工時 Investment costs, hourly rates from Germany 沒有熱回收 No heat recoveryTOTAL 8% 85,-Savings in % TotalCPU 7.2 EcoDS Savings年均節(jié)省成本年均節(jié)省成本1,100,000歐元歐元 / 7年內(nèi)成本節(jié)省: 7,700,000 歐元歐元Annual Costs Savings: 1.1 mill / Costs Savings within 7 ye

7、ars: 7.7 mill0.36.10.37.20.5總總CPU節(jié)省節(jié)省Total CPU Savings廠房成本廠房成本Building Cost維修成本維修成本Maintenance Cost材料成本材料成本Material Cost能耗能耗Energy Cost每輛車節(jié)省每輛車節(jié)省 Achieved savings in per vehicleEcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings- 30 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009成本效率和

8、節(jié)省資源成本效率和節(jié)省資源 Cost efficiency and resources savings 10%CPU節(jié)省節(jié)省 10% CPU savings 60%的能源成本節(jié)省的能源成本節(jié)省 60% Energy Cost Savings 35%減少截面積減少截面積 35% Reduced Cross Section 減少減少90%的顆粒排放的顆粒排放 90% Less Particle Emissions 100%不需要水系統(tǒng)不需要水系統(tǒng) 100 % Water savings from wet system 100%可回收預(yù)涂料可回收預(yù)涂料 100% Recycling of preco

9、at material 涂裝車間更環(huán)保涂裝車間更環(huán)保 Environmental improvement of the paint shopDry Separation at its bestEcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings- 31 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009EcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings例如例如Rehau Viechtach - 運行成本運行成

10、本 Example Rehau Viechtach - Cost of Operation數(shù)據(jù)采集于運行一年的數(shù)據(jù)采集于運行一年的Rehau項目項目Data base on the Rehau comparison after one year in operation- 24 %- 32 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009例如大眾埃姆登例如大眾埃姆登-經(jīng)營和投資成本費用經(jīng)營和投資成本費用 Example VW Emden Cost of operation and investment costs基礎(chǔ)的能源成本 B

11、asis for the energy costs: 4000小時/ 一個運行周期 4000 h/a operating time 2條底漆線 2 primer lines 2條面漆線 2 top coat lines 需要一個熱回收系統(tǒng) With a working heat recovery處理和供應(yīng)成本的基礎(chǔ) Basis for the costs of disposal and supply: 40 輛/ 小時，8料斗/區(qū)域 40 U/h and 8 hopper/zone 油漆污泥/凝結(jié)（用于處理和化學(xué)品成本）Paint sludge/coagulation (cost for di

12、sposal and chemicals) 預(yù)涂材料/過濾器（供水和污水處理和過濾器更換的費用）Precoat material/filter (cost for supply and disposal and filter change) 包括手工區(qū)域 Incl. manual zonesEcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings- 33 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009例如大眾埃姆登例如大眾埃姆登-運行成本運行成本 Example VW E

13、mden - Cost of OperationCost saving:成本減少 2.195.159 /a21.356.403 RMB/aEcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings- 34 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009EcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings例如大眾埃姆登例如大眾埃姆登-運行成本運行成本 Example VW Chattanooga - Cost of

14、 OperationData base on the calculation of VW Wolfsburg for the Project VW Chattanooga, USA4 /E1,42 /E- 75 % CPU- 35 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009議事日程議事日程 Agenda EcoDryScrubber 綠色解決方案綠色解決方案 The Green Solution EcoDryScrubber 動畫演示動畫演示 Movie EcoDryScrubber 技術(shù)技術(shù) Technology EcoD

15、ryScrubber 與濕式分離方式對比與濕式分離方式對比 vs. Wet separation EcoDryScrubber 成本和能源的節(jié)約成本和能源的節(jié)約 Cost & Energy Savings EcoDryScrubber 業(yè)績業(yè)績References- 36 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009EcoDryScrubber 業(yè)績業(yè)績 ReferencesProjects項目啟動 Start Project:01/2005試點工廠啟動 Start Pilot Plant:04/2007操作時間 Op

16、erating Hours: 1.500 hours正式演示 Official Presentation:10.2008項目正式完成 Official Project Completion:02/2009參與方 Involved parties: VW and Daimler杜爾試點工廠，德國杜爾試點工廠，德國 Drr Pilot Plant, Germany- 37 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009Projects車間類型 Type of Plant: 保險杠Bumper Production年產(chǎn)量 Annual

17、 Capacity: 最大 500.000 件.SOP:02/2009 應(yīng)用技術(shù)Application Technology: Drr EcoBell2 HDRehau 公司公司 維希塔赫，德國維希塔赫，德國 Rehau Viechtach, Germany客戶反饋Customer feedback 自SOP后生產(chǎn)沒有中斷 No production interruptions since SOP 整潔的系統(tǒng)和環(huán)境 Clean system and the surrounding 對設(shè)備性能和噴漆質(zhì)量表示滿意Satisfied with the system performance and p

18、aint quality 對系統(tǒng)運行非常滿意 Implementation of the system absolutely satisfactory 清潔觀念貫徹實施（清潔周期為3周，2班倒）Cleaning concept is functioning well (cleaning cycle 3 weeks, 2 shift production) 更好的涂料固體比：石灰石材是1:1（雙組分水性材質(zhì)） Better results in ratio paint solids : lime stone material is 1:1(2K Hydroprimer) 目前產(chǎn)能900 /天，2

19、班 Current production 900 units/day, 2 shifts EcoDryScrubber 業(yè)績業(yè)績 References- 38 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009Projects車間類型 Type of Plant:不同部件（如保險杠）Different parts (such as Bumper)年產(chǎn)能 Annual Capacity: up to 2.700.000 pcs.SOP:07/2009噴涂工藝:2 booths (2K Hydroprimer/1K WBC; 2K Cl

20、earcoat)應(yīng)用技術(shù): Drr EcoBell2 HDRehau 公司南非伊莉莎白港公司南非伊莉莎白港 Rehau Port Elizabeth, South AfricaEcoDryScrubber 業(yè)績業(yè)績 References- 39 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009Projects車間類型 Type of Plant:車體（新中型轎車）Car bodies (new midsize sedan)年產(chǎn)能 Annual Capacity: 31 U/h ca. 154.752 U/aSOP:04/2011應(yīng)

21、用技術(shù) Application Technology: RPL 133 (全自動噴涂fully automatic painting)噴涂系統(tǒng) Paint System:Process 2010 (primer-less process )美國大眾美國大眾 查塔努加市查塔努加市 VW Chattanooga, USAEcoDryScrubber 業(yè)績業(yè)績 References- 40 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009Projects車間類型 Type of Plant:車體（新中型轎車）Car bodies (ne

22、w midsize sedan)年產(chǎn)能 Annual Capacity: 62 U/h ca. 309.504 U/aSOP:09/2011應(yīng)用技術(shù) Application Technology: RPL 133 (全自動噴涂fully automatic painting)噴涂系統(tǒng) Paint System:Process 2010 (primer-less process) 中國中國成都一汽大眾成都一汽大眾 FAW VW Chengdu, ChinaEcoDryScrubber 業(yè)績業(yè)績 References- 41 - Drr Systems GmbH, PFS PSA, EcoDryScrubber, 29.10. 2009完全沒有風(fēng)險的新技術(shù)完全沒有風(fēng)險的新技術(shù) No Risks through New Technologies! 不粘附油漆分離技術(shù)Overspray binding technology 業(yè)績業(yè)績 References GM powder primer, 4 plants BMW powder CC, Leipzig, Dingolfingen, Regensburg Ferrari powder primer, Maranello Chrysler pow