Independent and environmentally friendly: electric ovens from Dürr significantly reduce CO2 emissions

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Bietigheim-Bissingen, September 02, 2022 – Climate neutrality, rising CO2 prices and uncertainties about natural gas supply are prompting automakers to step up their search for alternatives to gas-powered plants. In response, Dürr became the first supplier to electrify all body ovens in its portfolio. The first reference project with green electricity – used since 2018 in a paint shop in Scandinavia – proves that there is no change in the quality of the drying process, which remains at the highest level.

The biggest energy consumer in the drying process is the drying of the body. And its share in the CO2 footprint is therefore high. By switching from natural gas to regenerative energy such as green electricity, it is possible to reduce the CO2 emissions of a conventional paint shop by around 40%, which is a huge step towards climate-neutral production and a greater security of supply.

All Dürr ovens – from the traditional oven to EcoInnovative compact SmartCure EcoInCure with drying of the body from the inside – can work with the energy sources of the future. In addition to preferred green electricity, conversion to hydrogen and biogas is also possible. As a pioneer of electric ovens, Dürr demonstrates its expertise not only in the electrification of new ovens but also in brownfield renovations. The machine and plant engineering company offers individual assessments for existing plants to develop an optimal conversion concept so that manufacturers can achieve short conversion times and outstanding cost efficiency.

Reduce costs through energy efficiency
Further increases in fossil fuel prices are expected in the medium term, while the costs of regenerative plants decline as the number of plants installed increases.

“We have developed a complete concept with several energy efficiency modules so that car manufacturers can already use environmentally friendly green electricity for profitable production”, explains Heiko Dieter, Product Manager at Dürr Systems AG. “With a state-of-the-art insulation concept, skidless conveying technology and our EcoVEC Smart Oven Control System, we’re coming at it from many directions.”

Lowest exhaust air temperatures
The OxyThe .X.RV air pollution control system works electrically according to the principle of regenerative thermal oxidation (RTO). Dürr is the only supplier able to offer a complete concept consisting of electrically heated furnaces and electrical exhaust air after treatment. Electric heating uses the RTO method which decouples heating and air pollution control. Decentralized and compact individual units provide heat. The units have the added benefit of streamlining the layout since large duct systems to provide heat are no longer required. Thanks to highly efficient heat recovery, manufacturers can almost entirely use the energy from the exhaust airflow to heat the fresh air. This reduces energy losses via the exhaust air to an unprecedented level.

Power supply control according to needs
Another energy-saving tool is the predictive EcoIntelligent VEC system for controlling fresh and extract air. The intelligent software regulates the oven’s power consumption, adapting the energy demand to the exact number of bodies in the oven and reducing consumption when operating at part load. Switching to a skidless conveyor technology like Dürr’s traverse technology also saves energy since the oven heats up less material that needs to cool later.

No modification of the painting process with electric drying of the body
Dürr notes a strong increase in demand for electric ovens. “Currently, we have several projects underway. As the only paint shop supplier, we can offer a complete package for dryer electrification and air pollution control, combined with technologies for energy efficiency to reduce operating costs,” says Heiko Dieter. “We put all this into practice with products from our portfolio. For our customers, the switch to electric body drying is completely risk-free. Without changing the usual Dürr quality and without changing the drying conditions, the only change is in the energy source “.

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