Automotive
SMP Deutschland GmbH
Energy efficiency for a paint shop
SMP Deutschland GmbH contracted ÖKOTEC for the concept development, planning and tender, as well as project management, construction supervision and success monitoring.
The Challenge
SMP Deutschland GmbH is one of Europe’s leading plastic manufacturers and recognized partners in the automobile industry. As a specialist for complete systems and modules for the interior as well as exterior of vehicles, SMP Deutschland GmbH is located at sites in Europe, Asia and Latin America. SMP Deutschland GmbH produces plastic parts in the region Neustadt-Schwaig for the automobile industry. In factory 2 extensive energy efficiency measures have been implemented, leading to a reduction in the gas consumption for heat generation for the room- and car-wash plant by 53 percent, as well as a reduction of the electricity consumption for cooling supply by 33 percent.
“After the first projects, ÖKOTEC has helped us discover and successfully implementing broad energy-saving measures in the areas of cooling, heating, compressed air and process systems in factory 2. Our problems with capacity bottlenecking has been solved by the competent support from ÖKOTEC.”
Rudolf Lang
Head of installation engineering
Against the backdrop of the large demand for heating and cooling for the new high performance paint shop, a central waste-heat recovery (WHR) circle system was already considered and realized during its construction. The regulation of the waste-heat usage was not optimally adjusted, as well as not being hydraulically and technically optimized for the different temperature levels of the various heat sinks. As part of a detailed energy analysis, ÖKOTEC developed the idea to optimize the washing process, the existing WHR and cooling system. From measurements and information from the process control system, ÖKOTEC was able to determine the saving potential. SMP Deutschland GmbH decided, based on this analysis, to implement the project together with ÖKOTEC.
Solution and Implementation
- An additional WHR circuit with 300 m length of pipeline was installed
- New heat exchangers for the air compressors, desuperheater for chillers and extra feedback control were also installed
- At the washing street of the paint shop measures to optimize the inlet and exhaust-air flows, the regulation of heat transfer, the reduction of losses of water vapour, heat insulation and the optimization of the existing heat recovery have been realized
- Installation of a new cooling tower for free cooling and optimization of the chilled water supply and the control of the refrigeration compressors.
- Through the optimization of the modulation over a period of 3 month, more than 450 kW the planned waste-heat recovery has been achieved – without additional costs for SMP
Benefits
- Cost savings 670 T€/a
- Investment costs 1,155 T€
- Return on Investment period 1.6 a
- Internal rate of interest 57 %
- Annual gas savings of approx. 2,650 MWh
