task 1.2 energy-efficiency indices

1ARTISAN 1st ARTISAN 1st Plenary MeetingPlenary MeetingMay 8th – 9th 2012

ARTISAN 1st ARTISAN 1st Plenary MeetingPlenary MeetingMay 8th – 9th 2012

Task 1.2 Energy-efficiency indices

Angelo Frascella – Marco Zambelli



From DoW

• Goal: – Definition of indices for measuring the energy efficiency per

process along the supply chain• Activities & Outcomes:

– Starting from a literature review, the definitions of the indices will be finalized performing a phase of energy-consumption audits in participating user enterprises and selected external user enterprises from the European Textile industry

– Energy-consumption patterns will be identified– Further, the energy consumption models and profiles of the

textile sector, by generalizing the results of the analyzed enterprises, will be defined.

2



Preliminary Remarks



• The reference index is the energy requirements for surface area unit of fabric (kWh/m2)

• Considering that fabric production need electricity, heat and water there will be:– kWh (thermal) /m2 of final product– kWh (electric) /m2 of final product– Kg (H2O) /m2 of final product

– m3 (compressed air) /m2 of final product

Preliminary remarks



• Simplification hypothesis: the fabric is produced in a single environment that need air conditioning

• So it is possible to evaluate electricity (Ee) heat (He) and water (We) required for air conditioning

• Air conditioning needs are influenced not only by season, but also by climatic conditions, day and night differences, light irradiation and external humidity changes

• The features of surfaces (horizontal and vertical ones, opaque and transparent ones) affect air conditioning needs

Preliminary remarks: the building



Preliminary remarks: the process



• Each m2 of fabric will need a quantity of heat sum of:– Heat used by each machine– A portion of heat needed for heating the

environment

Preliminary remarks



Energy needs not related to the process



• Here will be considered energy needs for air conditioning, lighting and possible collective uses (baths, offices, …).

• They will be grouped under the voice “environment conditioning”

• For this kind of consumption, on first approximation, we can consider there is not direct proportionality with quantity of fabric produced in a year




Energy needs related to the process



• Direct proportionality with quantity of fabric produced in a year• Example of path of a product inside the plant:

a) Raw material in the loom: warping, drawing-in, weaving executionb) Control and possible darning of the rough productc) Finishing

a) Wet Finishing (Fulling…) , b) Dryingc) Raising that can be repeated, d) Dyeing, e) Dry Finisching (Polling …)

d) Final controls• For each of them there will be energy consumption (including water

and compressed air)• Energy consumption for time unit will be function of machine

parameters and of product features

Energy needsrelated to the process



• With reference to the previous process:– Loom operations needs electric power and compressed air. – loom speed can be function of yarn thickness (t) and weft

complexity (w)• The electric consumption of warping (Ew) will depends also from the

power of the electric engine (Mew)

Energy requirements related to the process

• The electric consumption of drawing-in (Ed) similarly will be:

• The electric consumption of weaving (Ewe) will depends also from the speed sw



• Darning is a manual operation which requires an electrical machine for fabric flowing:


• Wet finishing operations requires steam and heat for the right atmospheric conditions and also electrical power for flowing:



• In the same way consumption of drying, raising, …, can be defined.

• A particular operation is the dyeing which requires the immersion of fabric for a certain time in basins with hot colored water.– Energy needs could depends also on time (tu), color (cu), Temperature

(Tu), basin capacity (Vu) , Metu as the electrical power and Htu as the heating rated load




• The precise relations and dependencies have to be calculate by a measurement campaign that have to be programmed with Piacenza and DITF personnel

• Data collecting have to be homogeneous inside the two enterprises

• During these campaign can be examined also transitory (e.g. set-up consumptions) and stand-by consumptions

Energy requirements related to the process: notes



Global needs and indices



• If we refers all to the “hour”, in a hour they will be produced α m2 of fabric.

• The global Total Electric Consumption (TEC) will be:

Total electric consumption

Where K is the number of parallel processing and nst the number of repetitions of a step. Est will be: Ew, Ed, ...

This is a FIRST LEVEL index, giving a global data about consumptions Similar indices can be evaluated for heat, water and compressed air (Total

Heat Consumption, Total Water Consumption, Total Compressed Air Consumption)



• If it is desired the electric consumption (EC) for m2 of fabric for a certain model of fabric it will be:

Electric consumption for surface area unit

• On the base of the TEC a global electric energy index (EII) can be defined as:



• Moreover, for a certain model of fabric there will be specific indices for each step:

Other indices

These are SECOND LEVEL indices, giving specific data about steps Similar indices can be evaluated for heat, water and compressed air (Building

Thermal Efficiency Index, Wet Finishing Thermal Efficiency…)



No Name Indices 1 online monitoring of the process energy

consumptionSecond level process indices (WEEI, WFEEI…)

2 mapping of actual energy consumption to production orders

Consumption for for m2 of fabric for a certain model of fabric (EC, …)

3 energy consumption model for processes for different product groups: total for each reference entity

Second level process indices (WEEI, WFEEI…)

4 energy consumption model for processes for different product groups: time profiles for each reference entity

5 allocation of energy consumption caused by supporting infrastructure

BEEI, BTEI (Building Thermal Efficiency Index), …

Indices and data structure scenarios



Thanks for

your attention

task 1.2 energy-efficiency indices

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