new technologies for energy conservation in the textile industry · 2013-06-25 · energy use in...
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© Alcon Advies 2013
New technologies for
energy conservation in the textile industry
Anton Luiken
Alcon Advies BV
Wierden
The Netherlands
anton.luiken@alconadvies.nl
© Alcon Advies 2013
Energy use in the textile industry
• Textile processing is using much energy for
– Heating process water
– Drying textiles
– Drives of machines
– Climatizing rooms
• Energy reduction is a must to
– Reduce costs
– Better process control
– Improve the quality of the end-products
• Focus on reduction of energy use
– Good housekeeping measures
– New technologies
© Alcon Advies 2013
Energy conservation
• Inventory of processes and their energy use – monitoring
• Reduce losses by good housekeeping measures
– For example
• Reduce the amount of water in washing processes
• Reduce temperatures and amount of air in stenters
• Install energy conservation measures
– Heat exchangers
– Improve mechanical drying ( eg suction slots)
• New energy friendly proceses
– Low temperature
– Low water or dry processes
– Improved process control
© Alcon Advies 2013
Energy use – monitoring
• Monitoring is essential
- To see how the processes are performing
- How much energy you use for processing
- To calculate your standard energy use per unit of product
- To see deviations from the normal energy use – alert
- To be able to calculate the benefits of process changes,
investments, …
- More on this subject later this day.
© Alcon Advies 2013
New energy friendly processes
• Use of enzymes for scouring and bleaching in
pretreatment of cotton
• Plasma technology
• Ink-jet printing
• IR-drying
• Hot melt technology
• SC-CO2 technology
• UV-EB technology
© Alcon Advies 2013
Enzymes for scouring and bleaching
• Enzymes work at reduced temperatures under mild conditions
– 40-80 °C; pH 5-9
• Enzymes used long time for desizing and softening (bio-polish)
• Now also available for scouring and bleaching
http://primagreen.dupont.com/product-solutions/for-textile-mills/
© Alcon Advies 2013
Plasma technology
• Dry process for surface oxydation and surface
modification
– Removal of spinfinish (polyester)
– Soil release / hydrophobic finish
– Hydrophilic surface finish
– Adhesion promotor (for coatings and laminates)
• Reduction on chemicals: > 90%
• Reduction on energy: > 90%
• No drying or curing process needed
SDBD-plasma TNO (NL)
© Alcon Advies 2013
Inkjet printing
• Digital and minimum application
technology
• Reduced use of chemicals (dyes)
• No waste, no left-overs
• No cleaning of screens and printing blanket
– Huge saving of water
• Very efficient in printing
– No time loss due to design / color changes
– Options for mass customisation
• Energy reduction potential: > 75%
(including fixation)
• Water reduction in printing: > 50%
(including washing of unfixed dyes)
© Alcon Advies 2013
Gas fired IR drying
• Optimizing drying in the textile industry
– Fast reaction time on power change request
– Even heat distribution
– Controlled and adjustable energy output (wide range of control)
– For the process increased production speeds
– Improved efficiency/lower operating cost
– Width adjustable to the fabric
• Combination with stenter increases flexibility in production and the
drying capacity of the stenter
• Savings potential: 25% on drying energy
• More info: in workshop in afternoon
© Alcon Advies 2013
Hot melt technology
• Use of hotmelts in coating and laminating
• No evaporation of water or thermal curing
• Energy reduction potential > 70%
• Large range of products available
– Different melting temperature
• Melt is applied; immediate adhesion after cooling
– Reactive hotmelts (self curing)
• Coating with slot-die coater (kind of extruder)
Photo: Centexbel (B)
© Alcon Advies 2013
SC CO2-dyeing
• Water-free dyeing of Polyester
• Super critical CO2 as a carrier for dyes
• At the moment limited to the dying of polyester
and disperse dyes
• High quality end-product
• Reduction of dying time
• No afterwash (and drying needed)
• Is succesfull introduced in the market of
sportswear
• Energy saving potential > 90%
• More details in the afternoon workshop by
Dyecoo
© Alcon Advies 2013
UV-EB technology
• Curing of chemicals (coatings, finishes) needs high
temperatures at prolonged times
• By special chemistry curing times can be extremely
reduced
• By UV-technology curing is done in milli-seconds
• Used in textile industry especially for (clear) coatings and
in combination with ink-jet printing
• Energy saving potential > 80%
© Alcon Advies 2013
Conclusion
• Many new energy saving technologies are available or
will become available in a few years
• New technologies will help to
– Increase product quality
– Increase production flexibility
– Give options for mass customization
– Reduce environmental impact of textile processing
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