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, AirCompressing, 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 Auxillary 5%
Spinning 35%
Dyeing 40% Weaving 20%
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
service
Avoiding unnecessary consumption of energy
Shares of energy consumption and cost in various textile sectors of Mauritious (An Example)
Textile Sectors
Electrical energy, Total energy (KWh/kg) 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
0.30-0.45
Knitting
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 fitting Colour of the interior finish of the room should be bright Distance from the light source is important
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 transportation Using pressure reducing valves to regulate the steam pressure at the point of use Optimizing of boiler air/fuel ratio and operating pressure Useing demineralised water in boilers
BEE Sponsored project 9
Project Examined Technologies Energy Management System
Recovering of cooling water and heat recovery from hot/waste Recovering of condensate Useing 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 disposal Reduction in Energy consumption for heating
Savings due to efficient compressed air management in Punjab Mills (NITMA Sponsored Study) Project 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
Units
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 By Zenith 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 BEE Sponsored project
16
Installation of Economizer in Boilers •
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 17
Replace the old Boilers with Energy Efficient Boilers
BEE Sponsored project 18
Benefits
Reduces fuel consumption and faster generation of steam Reduces GHG emissions Improves working environment for workers due to reduction in radiation losses and flue gas temperatures
19
Cost Benefit Analysis Energy Conservation Measures
Monetary Savings Simple Payback (Rs.Lakh) 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 Cluster in 75 Units By Zenith 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 energy Total: 12, 89,039 TOE
Recommended Steam based cogeneration system Schematic Diagram Of Proposed Cogeneration Scheme Boiler High pressure Steam
TURBINE
Low pressure Exhaust Steam
~
POWER
To Process CO-GENERATION
BEE Sponsored project 23
Cost benefit analysis = 500 kW = 400 kWh = 5500 kg = 760 kg = Rs.2660 = Rs.2660 = Rs. (4910 – 2660) = Rs.2250 Monetary/annum = Rs.78.70 Lakh Capital invested for co-generation plant = Rs.350.00 Lakh Simple payback period = 4.4 years
Capacity of the co-generation plant No. of units generated/hr Steam generation Coal consumption Coal cost (Rs.3.50/kg) Total fuel cost Monetary savings/hr
BEE Sponsored project 24
Recommended to Generate hot water from hot drained water (heat exchangers) of Jet Machines
BEE Sponsored project 25
Cost benefit analysis Days of operation per annum Quantity of hot water drained Average quantity per day for conservative purpose (80%) Temperature of hot drain water Quantity of heat can be recovered Boiler efficiency Calorific value of fuel Fuel savings Fuel cost Savings per annum Investment for tank, heat exchanger and distribution system Payback period
350 Days 85,000 liters/day 68,000 liters/day 90o C 27,20,000 kcal/day 51% 5800 kcal/kg 292 tons/annum Rs. 3,500 per ton Rs. 10.22 Lakh Rs.6.00 Lakh 6 Months BEE Sponsored project 26
There is Scope of Energy Saving in Dyeing & Finishing Operation in Textile Mills of Punjab
Thank You
Save energy, save environment for future generation
