scope of energy saving in textile industry

Scope of Energy saving in textile mills of Punjab

By

J.N.Vohra B.Text, M.Tech, F.I.E., C.Eng (I), L.M.I.M.A.Coordinator-NITMA, Punjab

Types of energy used in the textile industry

Electricity:As power source for machinery, Lighting, Air-Compressing, and Air-Conditioning or Cooling

Fuel:For generating steam in Boilers for heating water, dye fixation, fabric drying, and temperature control systems

Energy Sources in Punjab

Electricity: Hydro-Power, Thermal

Fuel: Coal, Rice Husk, Fuel Oil, Wood

Energy Consumption Pattern in Punjab Textile Mills

Spinning

35%

Weaving

20%

Dyeing

40%

Auxillary

5%

Whereas, power dominates consumption pattern in spinning/weaving, while thermal energy, requiring use of fuel, is major for dyeing & finishing, for heating and drying of the water

used.

Energy Saved = 2 x Energy Produced

Energy efficiency usually refers to

Reduction in the energy usage for a given serviceAvoiding unnecessary consumption of energy

Shares of energy consumption and cost in various textile sectors of Mauritious

(An Example)

Textile Sectors Electrical energy, (KWh/kg)

Total energy cost, $/kg

Spinning 3.60-3.80 0.19-0.20 Weaving 2.00-2.20 0.12-0.13 Dyeing & Finish 1.60-1.70 0.30-0.45Knitting 0.30-0.40 0.02 Clothing Manufacture. 0.80-1.00 0.07-0.12

The wet processing of textiles consumes only a small portion of electrical energy, say around 16% of total electrical energy, mainly for running the

various processing machinery's.

For “rational use of energy”

General management techniques and

Process-specific techniques

General Management Techniques……to improve the efficiency of electricity use

(Small Measures)

Use Electricity-saving fluorescent lamps or economical florescent tubes. Ensure correct shape of the reflective fittingColour of the interior finish of the room should be brightDistance from the light source is important

9

Project Examined Technologies For effective use of steam

Useing appropriate heat insulating materials for steam piping Reduces steam leakages and consumption Using smaller distances for steam transportationUsing pressure reducing valves to regulate the steam pressure at the point of useOptimizing of boiler air/fuel ratio and operating pressureUseing demineralised water in boilers

BEE Sponsored project

Project Examined TechnologiesEnergy Management System

Recovering of cooling water and heat recovery from hot/wasteRecovering of condensateUseing of measuring instruments and automatic controls, Useing of heat exchangers and recovery systems

BEE Sponsored project

Water usage in Textile Industry

Major water uses in the textile industry may include:

washing/rinsing, scouring, dyeing and bleaching.

Values are indicative only and will vary from site to site.

Water saving benefits

There are significant benefits that can be realised through becoming more water efficient. These include reductions in costs in:Wastewater discharge; treatment and disposalReduction in Energy consumption for heating

Savings due to efficient compressed air management in Punjab Mills (NITMA Sponsored Study)

UnitsProject cost

(Rs. Lakhs)

Potential Power Savings in units/day

Potential Power Savings in Units per Annum

Potential carbon emissions in tons/annum

Savings in Rs Lakhs/an

num

1 5.25 750 270000.00 4.50 10.8

2 7.48 1750 630000.00 10.50 25.2

3 8.91 2100 756000.00 12.60 30.24

4 7.55 1750 630000.00 10.50 25.2

5 3.24 400 144000.00 2.40 5.76

6 26.86 7000 2520000.00 42.02 100.8

7 5.25 750 270000.00 4.50 10.8

8 5.25 750 270000.00 4.50 10.8

15250 5490000 91.53 219.6

Net Reduction Scope = 1.2 MW and Rs. 219.6 Lakhs/annum

The Energy use and Technology audit studies- Solapur Textile Cluster” in 51 units

ByZenith Energy Services (P) Limited, Hyderabad

Sponsored by

Bureau of Energy Efficiency (BEE)., New Delhi.600 Total Textile industries 350 units are of integrated 250 units have manual dyeing and 100 units has mechanical dyeing facility

Energy Scenario In Solapur Textile Cluster

Energy cost: 6 to 8% of the total production cost and varies as per the products manufactured.

Main energy forms: electricity and wood.

Energy consumption: 60 to 65% thermal energy & 35 to 40% electrical energy

Total: 16,647 TOE (tons of oil equivalent)

15

Recommended use of the Solar Hot Water System

• The solar energy is a renewable energy source and is available abundantly

• The Solar Hot water system doesn’t require any fuel

• The SHW system uses clean form of energy and doesn’t emit toxic gases and protects environment

• Subsidy from the central government, if loan is not taken from the financial institution, up-to 20% of total cost

16BEE Sponsored project

Installation of Economizer in Boilers

17

• Utilizes heat available in waste flue gases and hence no fuel is required

• Hot water generated can be directly used for the process, hence reduction in processing time

• Low investment and high returns

BEE Sponsored project

Replace the old Boilers with Energy Efficient Boilers

18

BEE Sponsored project

19

Reduces fuel consumption and faster generation of steamReduces GHG emissionsImproves working environment for workers due to reduction in radiation losses and flue gas temperatures

Benefits

Cost Benefit Analysis

Energy Conservation Measures

Monetary Savings (Rs.Lakh)

Simple Payback Period (in years

Total Saving Potential of the

cluster (Rs.Lakh)

Solar Hot Water System

0.60 3.3 90.00

Economizers (for boilers)

0.30 1.7 16.50

Heat recovery from hot drained water

0.50 _ 50.00

Energy Scenario In Surat Textile Clusterin 75 Units

ByZenith Energy Services (P) Limited, Hyderabad

Sponsored by

Bureau of Energy Efficiency (BEE)., New Delhi.

400 Total Textile industries 330 units are of integrated 70 units has dyeing facility

Energy Scenario in Surat Textile Cluster

Energy cost: 12 to 15% of the total production cost and varies as per the products manufactured

Main energy forms: Electricity ,Coal, Natural gas and Biomass .

Energy consumption: 60 to 65% thermal energy & 35 to 40% electrical energyTotal: 12, 89,039 TOE

23

Recommended Steam based cogeneration system

Schematic Diagram Of Proposed Cogeneration Scheme

TUR

BIN

E

~

To Process

POWER

CO-GENERATION

Boiler

High pressureSteam

Low pressure Exhaust Steam

BEE Sponsored project

24

Cost benefit analysisCapacity of the co-generation plant = 500 kWNo. of units generated/hr = 400 kWhSteam generation = 5500 kgCoal consumption = 760 kgCoal cost (Rs.3.50/kg) = Rs.2660Total fuel cost = Rs.2660Monetary savings/hr = Rs. (4910 – 2660)

= Rs.2250Monetary/annum = Rs.78.70 LakhCapital invested for co-generation plant = Rs.350.00 LakhSimple payback period = 4.4 years

BEE Sponsored project

25

Recommended to Generate hot water from hot drained water (heat exchangers) of Jet Machines

BEE Sponsored project

26

Cost benefit analysisDays of operation per annum 350 DaysQuantity of hot water drained 85,000 liters/dayAverage quantity per day for conservative purpose (80%) 68,000 liters/dayTemperature of hot drain water 90o CQuantity of heat can be recovered 27,20,000 kcal/dayBoiler efficiency 51%Calorific value of fuel 5800 kcal/kgFuel savings 292 tons/annumFuel cost Rs. 3,500 per ton

Savings per annum Rs. 10.22 LakhInvestment for tank, heat exchanger and distribution system Rs.6.00 LakhPayback period 6 Months

BEE Sponsored project

There is Scope of Energy Saving in Dyeing & Finishing Operation in Textile Mills of Punjab

Thank You

Save energy, save environment for future generation