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Up to 30% Less Energy Consumption in the Painting Process With the EcoDryScrubber From Dürr

Published on 2008-10-17. Author : SpecialChem

STUTTGART -- A new technology developed by Dürr enables energy savings of up to 30% in automobile painting, which is by far the most energy-intensive manufacturing process in the production of vehicles. The EcoDryScrubber system presented on October 15 works with recirculation of the booth process air and dry separation of the surplus paint particles during paint application. This leads to considerable improvements in energy consumption and in CO2 and paint particle emissions.

Ralf Dieter, Dürr AG's CEO, commented: "As technology leader Dürr addressed the issue of energy and CO2 optimization early on. We are therefore in a position today to offer our customers systems that allow significant reductions of energy and unit costs. Our dry separation system clearly underlines the results of our development efforts."

When applying wet paints, between 20% (manual painting) and 85% (automated exterior painting) of the material reaches the body, depending on the atomizers used. In the conventional process the rest of the paint, known as "overspray", is carried into the lower section of the spray booth where it is mixed with water. The booth process air is drawn off as, through the contact with water, it absorbs too much moisture for it to be re-used, and it also contains paint particle residues. As a result, a fresh supply of air has to be treated and fed to the booth, which consumes a lot of energy.

By contrast, spray booths equipped with the EcoDryScrubber require far less fresh air. The reason: the process air does not pick up additional moisture and the paint particles are completely removed in the dry filtration system beneath the booth, so the process air can be re-used. Water demand and maintenance costs go down as well. Moreover, the cross section of the building is being reduced, as EcoDryScrubber booths are equipped with Dürr´s new, space-saving EcoRP painting robots.

The air conditioning for the booths is the most energy-intensive part of the vehicle painting process. The optimizations achieved with the EcoDryScrubber therefore have a major impact on a paint system's total energy consumption. In a paint shop with an annual capacity of 158,000 car bodies, use of the EcoDryScrubber lowers energy consumption by 16 million kWh a year. This is equivalent to a reduction of 5,200 tonnes in CO2 emissions. Measured over a car model's total product life cycle of seven years Dürr's innovative solution can produce savings in the region of € 8 million.

The Dürr Group is a supplier of plant and equipment that commands leading global market positions in its areas of activity. Business with the automotive industry accounts for about 85% of its sales. Dürr also supplies innovative manufacturing and environmental technologies for the aircraft, mechanical engineering, chemical and pharmaceutical industries. The Dürr Group operates in the market through two divisions. The Paint and Assembly Systems division supplies production and painting technologies, mainly for automotive body & chassis manufacturing. The equipment and systems supplied by the Measuring and Process Systems division are used, among other things, for engine and transmission production and for final vehicle assembly. Dürr achieved sales of close to € 1.5 billion with approximately 6,000 employees in 2007. Dürr is present in 47 locations in 21 countries around the world.

Source: Dürr

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