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Assessment of the Automobile Assembly Paint Process for Energy, Environmental, and Economic Improvement

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  • Geoffrey J. Roelant
  • Amber J. Kemppainen
  • David R. Shonnard

Abstract

A coat of paint adds considerable value to an automobile. In addition to consuming up to 60% of the energy needed by automobile assembly plants, however, the painting process also creates both economic and environmental impacts. This study investigated the degree of cost and environmental impact improvement that can be expected when modifications are considered for existing paint processes through heat integration. In order to accomplish this goal, a mathematical model was created to describe the energy use, costs, and environmental impacts from energy consumption in an automobile assembly painting facility. The model agrees with measured energy consumption data for process heating and electricity demand to within about 15% for one Michigan truck facility from which model input parameters were obtained. Thermal pinch analysis determined an energy conservation target of 58% of paint process energy demand. A heat exchanger network optimization study was conducted in order to determine how closely the network design could achieve this target. The resulting heat exchanger network design was profitable based on a discounted cash flow analysis and may achieve reductions in total corporate energy consumption of up to 16% if implemented corporatewide at a major automobile manufacturer.

Suggested Citation

  • Geoffrey J. Roelant & Amber J. Kemppainen & David R. Shonnard, 2004. "Assessment of the Automobile Assembly Paint Process for Energy, Environmental, and Economic Improvement," Journal of Industrial Ecology, Yale University, vol. 8(1‐2), pages 173-191, January.
  • Handle: RePEc:bla:inecol:v:8:y:2004:i:1-2:p:173-191
    DOI: 10.1162/1088198041269355
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    Cited by:

    1. Giampieri, A. & Ling-Chin, J. & Ma, Z. & Smallbone, A. & Roskilly, A.P., 2020. "A review of the current automotive manufacturing practice from an energy perspective," Applied Energy, Elsevier, vol. 261(C).
    2. Mayyas, Ahmad T. & Qattawi, Ala & Mayyas, Abdel Raouf & Omar, Mohammed A., 2012. "Life cycle assessment-based selection for a sustainable lightweight body-in-white design," Energy, Elsevier, vol. 39(1), pages 412-425.
    3. Geldermann, Jutta & Treitz, Martin & Rentz, Otto, 2006. "Integrated technique assessment based on the pinch analysis approach for the design of production networks," European Journal of Operational Research, Elsevier, vol. 171(3), pages 1020-1032, June.

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