EWR 2 Calculator

For an initial assessment, use this calculator to calculate your individual savings potential in shielding gas costs and emitted CO₂ – which you can achieve with the integrated gas management system EWR 2. With six easy to determine factors, the calculator calculates your gas consumption with and without EWR 2, the savings in emitted carbon dioxide and the corresponding saved shielding gas costs. With just a few clicks, you can see and decide whether the EWR 2 from ABICOR BINZEL makes sense as a gas management system for your production. Our field representatives will be happy to carry out precise measurements at your site to identify your individual potential. 

This calculator serves as a first estimate. The data may vary according to your situation.

Explanation of the individual steps:

Step 1

First enter the shielding gas consumption per day. If you do not know this value, you can find it out in just a few steps with the second calculator »Calculate gas consumption«. For this purpose, enter the shielding gas volume flow set at the welding workstation (approx. 12–20 litres per minute) as well as the number of welding workstations. Bear in mind that each welding workstation requires its own gas management system.

Step 2

Next, in addition to the daily working time per shift minus breaks, also enter the number of working shifts at the welding workplaces per day (1–3). Then enter the duty cycle as a percentage, i. e. the percentage of time that welding is actively carried out during the work shift. This automatically calculates the welding time in minutes per day and at the same time the gas consumption per day in litres per day.

Step 3

Now select the type of shielding gas set at the workstation in the drop-down menu »Gas type«, e. g. 18/82.

Step 4

Select the gas supply type: a single gas bottle, a gas cylinder bundle, or a ring line with a gas tank behind it. From these two values we give an assumed value for the gas price in € per liter, since gas prices in € per liter are often difficult to determine. In this assumed value also additional costs like transport costs have been included. Understandably, these values may differ from your actual purchase prices and should only serve as an approximate value at this point. You can also enter the gas price in € per liter, € per m³ manually.

Schritt 5

Now enter the effective gas savings with the EWR 2. The exact value can be determined on site in a trial order. Again, we give an assumed value, which has proven to be an empirical value in the past and may deviate with your individual welding task. In the case of a manual welding process, this is 40 % and in the case of a partially automated welding process, 30 %. For a fully automated welding process (robot) we suggest to calculate with 50 %.

Step 6

Finally, enter the working days per month to get the result on a monthly basis. Consumption and savings are calculated automatically as you enter your data.

The calculator result

In the result, you will first find the gas consumption and the possible saving per month with the EWR 2. Next, depending on the gas consumption, the gas type and the effective gas saving, there is the saving of emitted carbon dioxide per month. This value describes the prevented carbon dioxide pollution of the atmosphere, which is calculated by the pure CO₂ content of the shielding gas. In addition, the carbon dioxide saved by reducing the production and transport of shielding gases is added. We have calculated a factor for you here, which provides an estimated value as an assumption. This is followed by the gas costs per month that you have according to the calculation values without and with EWR 2. This results in the effective gas cost savings in € per month.

Feel free to try out this calculator. Is the result interesting for you? You can test the EWR 2 gas management system live in your production and see what is possible for you in terms of saving gas. Contact us!