JEC 030916 wide FINALR2

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JEC 030916 wide FINALR2

  1. 1. 1 Copyright 2015 Split-zone Oxidation - The Bridge to 5,000+ tonne Automotive & Industrial Carbon Fiber lines Business Case Review JEC Paris March 9, 2016
  2. 2. 2 Copyright 2015 AGENDA 1. Why Split-zone oxidation? 2. What is Split-zone’s savings potential? 3. How can Split-zone facilitate 5000+ tonne automotive and industrial carbon fiber lines? 4. How can I prove Split-zone performance for myself?
  3. 3. 3 Copyright 2015 • Why Split-zone? Conventional oxidation is a prime candidate for innovation It’s a costly process step • The large number of Oxidation ovens (typically 3or 4) in a carbonization line represent one of the largest capital equipment investments • Their large factory footprint increases the facility and facility infrastructure costs • Oxidation ovens uses lots of energy There’s plenty of room for improvement • Oxidation is the longest process cycle, by far, of the three thermal steps • There is potential to reduce current oxidation cycle times closer to the theoretic cycle time • There is a great need to reduce oxidation Cost of Operation
  4. 4. 4 Copyright 2015 Automotive Carbonization line with Conventional Oxidation
  5. 5. 5 Copyright 2015 • Why Split-zone? Conventional oxidation is a prime candidate for innovation What’s needed is needle-moving innovation that can both reduce the oxidation total cycle time and can reduce the number of Oxidation ovens
  6. 6. 6 Copyright 2015 -CONVENTIONAL- Oxidation -UNDEVELOPED- Technology Island -IDEAL- Large scale, short cycle time, low cost of operation Emissions Contamination Scalability - NEEDLE-MOVING - improvement in Oxidation Cycle time Cycle Time Energy UsageRobustness Oxidation Innovation Roadmap Oxidation Innovation Roadmap High Capex Footprint Availability
  7. 7. 7 Copyright 2015 -CONVENTIONAL- Oxidation -UNDEVELOPED- Technology Island -IDEAL- Large scale, short cycle time, low cost of operation Emissions Contamination Scalability LOWER Cost of Operation is the desired result - NEEDLE-MOVING - innovation in Oxidation Cycle time Cycle Time Energy UsageRobustness Oxidation Innovation Roadmap Oxidation Innovation Roadmap High Capex Footprint Availability
  8. 8. 8 Copyright 2015 Despatch’s Proven Track Record of Oxidation Oven Technology Innovation 1970’s • Entered CF oxidation oven market with opposing cross flow ovens 1980’s • Built 1st Center-to-Ends flow oxidation for Courtaulds • Patented CTE oxidation (1982) 1990’s • Built 1st Center-to-Ends flow oxidation oven 2000’s • Established CTE oxidation as the preferred technology • Progressively scaled “craft build” from 1.0 to 3.0m+ 2010 – 2013 • Global Expansion (6 wins in 6 months) • Delivered integrated pilot & research CF lines • Launched high capacity automotive oxidation ovens 2013 – 2015 • Implemented standardization & DFM on Legacy product • Developed and Launched Split-Zone Oxidation
  9. 9. 9 Copyright 2015 Illinois Tool Works – A Strong Corporate Parent Industrial Machinery Industry RANK2014 Illinois Tool Works 1 Parker-Hannifin Dover Corporation Flowserve Company 2 3 4 SPX Corporation 5 Illinois Tool Works REVENUE RANK 2012 $13.9B 149 2013 $14.1B 155 2014 $14.5B 171
  10. 10. 10 Copyright 2015 Oxidation Innovation Roadmap -CONVENTIONAL- Oxidation -UNDEVELOPED- Technology Island -IDEAL- Large scale, short cycle time, low cost of operation Emissions Contamination Scalability OBJECTIVE - Lower the cost of Operation up to 50% by accelerating the rate of oxidation by 10% - 25% - NEEDLE-MOVING – 10% - 25% improvement in oxidation cycle time Robustness Availability
  11. 11. 11 Copyright 2015 Despatch Product Development Plan
  12. 12. 12 Copyright 2015 Split-Zone simplicity = Needle-moving Innovation Double the number of independent temperature set points in each oven, enabling a faster oxidation process cycle Despatch Product Development Plan Lower temperature in lower half Higher temperature in upper half
  13. 13. 13 Copyright 2015 Split-Zone simplicity = Needle-moving Innovation Double the number of independent temperature set points in each oven, enabling a faster oxidation process cycle Despatch Product Development Plan Higher temperature in upper half can increase the rate of oxidation
  14. 14. 14 Copyright 2015 Split-zone Differential Temperature Characterization FIRST LOOK
  15. 15. 15 Copyright 2015 15 SET-UP: Simulated fully-loaded 3m tow band using Fiberglass Cloth
  16. 16. 16 Copyright 2015 Split-Zone simplicity = Needle-moving Innovation NOTE: DESPATCH CENTER TO ENDS AIRFLOW IS FROM CENTER SUPPLY NOZZLES TO RETURNS ON BOTH ENDS OF THE OVEN
  17. 17. 17 Copyright 2015 17 Split Zone Differential Temperature Performance Results Blended Profile at 10C° Set point Differential Observations • Differential temperature meet s or exceed 10C° between upper &lower half • Blended Profile • Blended profile in a fully loaded oven is confined to 2-3 middle passes, only, with remaining passes close to respective set point temperatures Transition Zone Transition Zone 190°C Set point 200°C Set point 200°C Set point 190°C Set point
  18. 18. 18 Copyright 2015 18 Split Zone Differential Temperature Performance Results Blended Profile at 10C° Set point Differential Conclusion • Split-zone PERFORMS AS INTENDED by creating two distinct temperature zones, capable of 10C° or more of separation, with a minimal blended zone Transition Zone Transition Zone 190°C Set point 200°C Set point 200°C Set point 190°C Set point
  19. 19. 19 Copyright 2015 Split-Zone simplicity = Needle-moving Innovation LOWER HALF STABLE TEMP ZONE UPPER HALF STABLE TEMP ZONE BLENDED ZONE
  20. 20. 20 Copyright 2015 Split-Zone Cost of Operation Business Case Despatch Cost of Operation Business Case
  21. 21. 21 Copyright 2015 What is Split-zone’s Cost of Operation Savings potential? 3m Carbonization Line Comparison between Conventional and Split-zone Oxidation • Total Heated Length – 3 Legacy Ovens with 69 total passes@12.17m/pass (840m total heated length) – 2 Split-zone Ovens with 42 total passes@ 15m/pass (630m total heated length) • Utility Costs – Legacy with electric heating @ utility cost of $0.105/kwh – Split-zone with gas heating @ utility cost of 0.034/kwh equivalent • Line Speed – Equivalent line speed of approximately 10m/min Despatch Cost of Operation Business Case
  22. 22. 22 Copyright 2015 Oxidation Utility cost comparison Despatch Cost of Operation Business Case Disclaimer: stated costs are estimates, only; changes to assumptions, such as annual capacity, # of zones, or operating temp can effect actual energy costs per ton 0% Cycle Time Improvement 25% Cycle Time Improvement 3.0m Legacy $843 3.0m Split Zone $437 $321 $- $100 $200 $300 $400 $500 $600 $700 $800 $900 EnergyCosts UTILITY Operating Costs per Ton
  23. 23. 23 Copyright 2015 Oxidation Cost of Operation comparison Despatch Cost of Operation Business Case 0% Cycle Time Improvement 25% Cycle Time Improvement 3.0m Legacy $1,398 3.0m Split Zone $1,114 $734 $- $200 $400 $600 $800 $1,000 $1,200 $1,400 $1,600 Depreciation+UtilityCosts Cost of Operation per Ton Disclaimer: stated costs are estimates, only; changes to assumptions, such as annual capacity, # of zones, or operating temp can effect actual energy costs per ton Up to a 47% reduction
  24. 24. 24 Copyright 2015 The Bridge Potential of Split-zone to facilitate large capacity automotive carbonization lines Current Situation • An estimated cost for fully functional* factory floor space for an industrial carbon fiber line is $200 - $250/ft2 ($2,152 - $2,690/m2) – *includes overhead and underground electrical and mechanical • The time to complete and commission a new CF plant can be 2 years, or longer Assessment In a series-production vehicle lightweighting application requiring many thousands of tonnes/a of carbon fiber, the number of plants, and lines, required are not economical at today’s nameplate capacity Despatch Bridge Potential
  25. 25. 25 Copyright 2015 The Bridge Potential of Split-Zone to facilitate large capacity automotive carbonization lines Despatch Bridge Potential FOR YOUR CONSIDERATION - Split-zone’s fewer and larger oxidation ovens can enable an increase in nameplate production capacity by up to 2 times within the same fixed factory footprint AND at a far lower cost of operation that helps to make automotive carbon fiber economical
  26. 26. 26 Copyright 2015 Proving Split-Zone Performance and Cost of Operation Validation Despatch Qualification and Validation ACTIVITY BENEFIT Demonstrate split-zone temperature differential under simulated production conditions Enables Customers to model their oxidation process profile/cycle time reduction using split zone profile data Conduct precursor validation trials under simulated production conditions Validate cycle time reduction potential and oxidation towband uniformity running up to 24 large tow across L,M,R sides of 3m oven Update Cost of Operation and Productivity Models Determine optimum length and number of ovens; establish the cost of operation savings for 5,000+ tonne nameplate capacity
  27. 27. 27 Copyright 2015 Customer Validation Trials coming June, 2016 Contact steve.oman@despatch.com for reservations and information

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