Introduction to Energy Efficiency, Approach and Working Steps

Windsor Hotel, Bangkok27 October 2010

Training on “Reducing Carbon Foot Print in Textile Industries”

Dr. Balasankari B.E., M.Engg., Ph.DArul Joe Mathias B.E., M.Engg., MBA

Introduction to Energy Efficiency

ENERGY EFFICIENCY - DEFINITION

• Refers to how effectively energy is being used for a given purpose

• Represents how efficiently energy is converted from one form to another

• Method of using less energy to perform the same function

WHY ENERGY EFFICIENCY?

• Due to limited availability of fossil fuels

• To avoid wastage of resources, electricity, thermal energy

• To reduce climatic change impact

• To reduce environmental issues

BENEFITS

• Reduces energy consumption

• Reduce water and material consumption

• Improves productivity with given energy

• Increases profits

BENEFITS

• Reduces dependence on conventional resources

• Environmentally beneficial

• Reduces air pollution

• Reduces global warming

Energy Efficiency Approaches & Working Steps

APPROACHES

Energy Efficiency involves :

▪ Energy audit & report

▪ Setting up energy management program

ENERGY AUDIT

• First step to improve energy efficiency

• Tool for energy efficiency improvement

ENERGY AUDIT - TYPES

• Walk through audit

• Utility cost analysis

• Standard energy audit

• Detailed energy audit

WALK THROUGH AUDIT

• Short site visit of the facility

• Identification of areas of simple and inexpensive actions

possible

• Goal: Immediate energy and/or operating cost savings

UTILITY COST ANALYSIS

• Evaluation of metered energy uses, operating costs and

utility data for several years

• Identification of energy use, peak demand, weather

effects, and potential for energy savings

STANDARD ENERGY AUDIT

• Comprehensive energy analysis

• Development of baseline for the energy use of the

facility

• Identification of energy conservation measures

• Evaluation of energy savings and cost effectiveness

DETAILED ENERGY AUDIT

• Similar to standard energy analysis, but time consuming

• Use of instruments to measure energy use

• Analysis of measured data

• Identification of energy efficiency measures and

potential for energy savings

ENERGY AUDIT REPORTS

• Designed to encourage implementation

• Recommendations to achieve energy efficiency and

energy cost saving

CONTENTS OF AUDIT REPORT

• Energy management plan

• Energy action plan

• Energy financing options

• Maintenance recommendations

• Standard calculation and assumptions

• Audit recommendations

ENERGY MANAGEMENT PROGRAM

ENERGY MANAGEMENT PROGRAM

• Most successful and cost effective way

• It begins with strong organizational commitment to continuous improvement of Energy Efficiency

• It involves:

Assigning management duties to energy director

Establishing energy policy

Creating cross functional energy team

ENERGY MANAGEMENT PROGRAM

• Steps to assess performance through:

Regular review of energy data

Technical assessment and

Bench marking

• From this, develop:

Baseline energy use

Goals for improvement (implementation of action plan)

MAKE COMMITMENT

• Commitment by management to energy management

program

• Assignment of energy management coordinator

• Creation of energy management committee of major

plant and department representatives

ASSESS PERFORMANCE

• Review of historical patterns of fuel and energy use

• Facility walk-through survey

• Preliminary analyses, review of drawings, data sheets, equipment specifications

• Development of energy audit plans

• Conduct of facility energy audit for processes, facilities and equipment

ASSESS PERFORMANCE

• Calculation of annual energy use based on audit results

• Comparison with historical records

• Analysis and simulation to evaluate energy management

options

• Economic analysis for energy management options (life

cycle costs, rate of return, cost benefit ratio)

SET GOALS

• Establish energy effectiveness goals for the organization

and individual plants

• Determine capital investment requirements and

priorities

• Establish measurement and reporting procedures

• Install monitoring and recording instruments

CREATE ACTION PLAN

Define technical steps and targets

Crete performance target for each facility, operation etc.

Set timelines for action

Establish monitoring system

Determine roles and resources

Internal roles (personnel in the plant)

External roles (consultant, service providers, vendors etc.)

Determine resources (in terns of human resource and cost)

IMPLEMENT THE ACTION PLAN

• To implement actions plan:

Create a communication plan with workers

Raise awareness to them

Build capacity

Motivate working personnel

Tract and monitor

EVALUATE PROGRESS

• Evaluate the progress in plants through:

Energy data

Review of activities as a part of action plan

Compare them to established goals

• Revise the action plan based on results

Introduction to Textile Industry

TEXTILE INDUSTRY

• Textile industry – one of the major energy consuming

industry

• Energy plays important role in manufacturing process

• Cost of energy is a major factor, next to chemical cost

SECTORS IN TEXTILE INDUSTRY

• Spinning (blending, carding, combing, drawing, simplex and spinning)

• Weaving/Knitting

• Wet processing (desizing, scouring, bleaching, mercerizing, printing, dyeing and finishing)

• Garment manufacturing

TEXTILE INDUSTRY

• Spinning and Weaving/knitting – large scale

• Spinning and Weaving/knitting combine together known as composite unit

• Wet processing – small scale

• Garment Manufacture – medium scale

RAW MATERIALS

Natural fibers :

• Cotton

• Wool

• Silk

• Flax

• Jute

Man-made & synthetic fibres:

•Polyester (PES)

•Polyacrylonitrile (PAC)

•Polyacrylonitrile (PAC)

•Polypropylene (PP)

•Elastane (EL)

PRODUCTION PROCESSES

• All processes do not occur in a single facility

• Processes and technologies differ across factories

• Numerous technologies

• Depends on type of raw material and expected product output

PRODUCTION PROCESSES

• Different methods available (for spinning, weaving, dyeing, printing etc.)

• Uses large quantity of electricity and fuel

• Electricity or fuel depends on type of industry

Spun yarn spinning – electricity use is more

Wet processing – fuel use is more