Full body powder antichip. Final report Page: 3 of 10
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04/17/96 09:29 .. .810.776 2009
APR 17 '96 10:16 FR PAINT AND ENERGY MGT 810 776 2009 TO 813027396242 P.04/15
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The burners in the air supply houses must heat the average annualtemperature of 550
F (from the U.S. Weather Bureau) to the 700 F required for the application of either
coating. Because the air in the powder booth is not solvent laden, 80 to 100 percent
of the air may be recycled back to the booth. The reduction -in the quantity of air
required for the smaller, reduced downdraft powder booth and the ability to recycle
means-that a much smaller quantity of air must be heated. Utilizing the temperature
differential, the volumetric air flow, and the fact that .018 BTU's are required to raise
one (1) cubic foot of air one (1) degree Fahrenheit, Table 3 of the appendix
demonstrates the energy required for heating the booth to normal operating
temperature. Art annual energy savings of 2.26 X 1010 BTU has been estimated.
Ovens must also be ventilated to prevent a hazardous build-up of volatile solvents. The
NFPA 86-A requires 10,000 cubic feet of air for each gallon of solvent evaporated in
a liquid. paint system. Although the powder oven air supply is not solvent laden, the
NFPA applies a safety factor of nine percent (9%) for the volatile content in powder
coatings and recommends 1500 cubic feet for each pound of these assigned volatiles.
Again, the quantity of fresh air required and therefore the energy necessary to raise
it to curing temperature are both greatly reduced as is shown in Table 4 in the
appendix. An annual energy savings of 2.60 X 10'3 BTU/yr per powder booth is
estimated when compared to the liquid spray booth.
The liquid paint spray systems include incineration of the oven volatile organic
compounds (VOC's) at 15000 F. Since there are minimal VOC's in powder coatings
and the only possible releases occur only during polymerization, incineration is not
required. The associated annual savings resulting from the elimination of the
incinerator utilized on the liquid spray system is 1.44 x 1010 BTU's per unit installed,
as can be seen in Table 5 of the appendix.
The total annual energy savings estimated in Table 7 for the successful implementation
of this full body powder antichip system rather than a liquid paint spray system are
estimated to be 4.07 X 1010 BTU's. For the sixteen year period between 1995 and
2010, a single powder antichip booth will result in a energy consumption reduction of
8.52 X 10" BTU's.
The annual cost savings is approximately $388 thousand, far below the original
estimates. In the original submission, the largest contributor was the annual material
cost savings, estimated to be $3.804 million per year at a production rate of 74
vehicles per hour. Because of reduced market demand, the plant ran at a reduced
production rate of 42 vehicles per hour. In addition, the original utilization efficiency
of 95% has not been achieved due to an unknown source of contamination of the
recycled powder. The utilization efficiency achieved in the plant has been 58%. As a
result of the lowered production and utilization, Newark has realized a disappointing
annual material cost savings of $296,563. Chrysler is working diligently to improve
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Full body powder antichip. Final report, report, April 17, 1996; United States. (digital.library.unt.edu/ark:/67531/metadc670047/m1/3/: accessed November 13, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.