Energy Conservation Potential Energy Conservation Potential in Textile Sector-Pakistanin Textile Sector-Pakistan

ByBy

Shafqat UllahShafqat UllahProgramme ManagerProgramme Manager

Programme for Industrial Sustainable Development (PISD)Programme for Industrial Sustainable Development (PISD)CPI & Royal Netherlands Embassy InitiativeCPI & Royal Netherlands Embassy Initiative

CPICleaner Production Institute

Key Areas of ConcernKey Areas of Concern

Lack in knowledge (energy wastages and energy saving potential)Lack in knowledge (energy wastages and energy saving potential)

Untrained and uneducated human resourcesUntrained and uneducated human resources

Old, inefficient, discarded machines Old, inefficient, discarded machines Lack in monitoring aptitudeLack in monitoring aptitude

Inefficient in resource consumption (water, chemicals, energy)Inefficient in resource consumption (water, chemicals, energy)

Improper maintenance and upkeepImproper maintenance and upkeep

Resource Consumption PracticesResource Consumption Practices

ResourceResource ConsumptionConsumption

(per Kg of Fabric (per Kg of Fabric Processed)Processed)

Optimum Optimum ConsumptionConsumption

Saving Saving PotentialPotential

%%

WaterWater 100-400 liter100-400 liter 70-10070-100 30-7530-75

ElectricityElectricity 0.5-2.0 kWh0.5-2.0 kWh 0.5-1.00.5-1.0 Up to 50% Up to 50%

Natural GasNatural Gas 0.5-2.0 m0.5-2.0 m33 0.5-1.00.5-1.0 Up to 50%Up to 50%

SteamSteam 5-15 kg5-15 kg 5-85-8 Up to 47Up to 47

Monitoring and MeasurementMonitoring and Measurement

Water consumption (Water flow meters)Water consumption (Water flow meters)

Steam consumption (steam flow meters)Steam consumption (steam flow meters)

Gas consumption Gas consumption (already in practice)(already in practice)

Electricity consumption Electricity consumption (already in practice)(already in practice)

Monitoring of process control parameters (Temperature, pH, concent. etc)Monitoring of process control parameters (Temperature, pH, concent. etc) Rs. 1.3/mRs. 1.3/m33-C-Coo (Rs. 7.0 million/year) (Rs. 7.0 million/year)

Process benchmarking Process benchmarking

Monitoring and MeasurementMonitoring and Measurement

Water QualityWater Quality

Product Quality DeteriorationProduct Quality Deterioration

More washesMore washes

More energyMore energy

More chemical consumptionMore chemical consumption

Scale in the machineScale in the machine

More blow downs More blow downs

Reverse Osmosis, Softeners, FiltersReverse Osmosis, Softeners, Filters

Electricity Vs ProductionElectricity Vs ProductionGas Vs Electricity GenerationGas Vs Electricity GenerationGraphical PresentationGraphical Presentation

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electricity (kWh) Gas (m3)

Maintenance & UpkeepMaintenance & Upkeep

Placement/upkeep of steam traps (Savings-Rs. 40,000-50,000/year-trap)Placement/upkeep of steam traps (Savings-Rs. 40,000-50,000/year-trap)Payback 3 monthsPayback 3 months

Steam leakage control (Savings-Rs. 100,000/year-leak control)Steam leakage control (Savings-Rs. 100,000/year-leak control) Payback 2 monthsPayback 2 months

Insulation of hot pipelines and surfaces (Savings-Rs. 4,000-5,000/year-m)Insulation of hot pipelines and surfaces (Savings-Rs. 4,000-5,000/year-m) Payback 6 monthsPayback 6 months

Maintenance of machines (optimum resource consumption, noise control)Maintenance of machines (optimum resource consumption, noise control)

Steam and air distribution system (pressure drops due to bends, long pipe Steam and air distribution system (pressure drops due to bends, long pipe lengths, slope of the lines, condensate removal, temperature and pressure lengths, slope of the lines, condensate removal, temperature and pressure gauges) gauges)

Process/Machines ModificationProcess/Machines Modification

Countercurrent washing sequence (bleaching, mercerization, dyeing etc.)Countercurrent washing sequence (bleaching, mercerization, dyeing etc.)(Savings-Rs. 800,000-1,000,000/year-machine)(Savings-Rs. 800,000-1,000,000/year-machine)Payback 1 monthsPayback 1 months

Process/Machines ModificationProcess/Machines Modification

Spring operated or automatic water shut off valves on water hoses or at Spring operated or automatic water shut off valves on water hoses or at machines inletsmachines inlets

Oversized steam boilers (1 ftOversized steam boilers (1 ft22 heating surface area = 3 kg steam/hr) heating surface area = 3 kg steam/hr)

Recovery & ReuseRecovery & Reuse

Recovery of heat from hot wastewater (Heat exchanger)Recovery of heat from hot wastewater (Heat exchanger)(Savings-Rs. 900,000-1,000,000/year)(Savings-Rs. 900,000-1,000,000/year) payback 6 monthspayback 6 months

Recovery of heat from exhaust gases of steam and therm oil boilers, Recovery of heat from exhaust gases of steam and therm oil boilers, generators-Boiler exhaust gases (Economizer)generators-Boiler exhaust gases (Economizer)

(Savings-Rs. 1,800,000-2,000,000/year)(Savings-Rs. 1,800,000-2,000,000/year) Payback 6 monthsPayback 6 months

Recovery & ReuseRecovery & Reuse

Reuse of steam condensate as boiler feed waterReuse of steam condensate as boiler feed water(Savings-Rs. 500,000-600,000/year)(Savings-Rs. 500,000-600,000/year)Payback 8 monthsPayback 8 months

Reuse of cooling water (compressor, pumps, therm oil boilers, chillers, jets) Reuse of cooling water (compressor, pumps, therm oil boilers, chillers, jets) (Savings-Rs. 50,000-100,000/year)(Savings-Rs. 50,000-100,000/year) Payback 6 to 12 monthsPayback 6 to 12 months

Reuse of RO rejected water for washing of floors and containersReuse of RO rejected water for washing of floors and containersResource conservationResource conservation

Reuse of inter process washes (Desizing, scouring, bleaching, mercerization)Reuse of inter process washes (Desizing, scouring, bleaching, mercerization) Resource conservation (Energy and water)Resource conservation (Energy and water)

Reuse of waste streams (mercerization waste stream for scouring bath) Reuse of waste streams (mercerization waste stream for scouring bath) Pollution reduction/resource conservation (Rs. 1,000,000/year)Pollution reduction/resource conservation (Rs. 1,000,000/year)

Compressed Air SystemCompressed Air System

5% of electrical energy is converted into 5% of electrical energy is converted into compressed compressed air energyair energy

Screw type compressors are more energy efficient Screw type compressors are more energy efficient than than piston typepiston type

Air quality (Moisture and Temperature)Air quality (Moisture and Temperature)

Cooler air intake (2.7Cooler air intake (2.7ooC drop in intake air temp, C drop in intake air temp, reduces reduces 1% energy)1% energy)

Distribution system (Pressure Drop), air leakagesDistribution system (Pressure Drop), air leakages

Cleaning points (Large diameter pipelines, air Cleaning points (Large diameter pipelines, air guns) – Instead of 8.5 mm dia, use 6 guns) – Instead of 8.5 mm dia, use 6

mm dia hosemm dia hose

Electrical ConsumptionElectrical ConsumptionEstimated Load Distribution Estimated Load Distribution

Department Designed Load (kW) % Share

Blow Room 275 5.7

Carding 385 8.0

Comber 70 1.5

Lap Former 25 0.5

Drawing 110 2.3

Simplex 115 2.5

Ring Frames 2050 42.8

Auto Cone & Comp. 375 7.8

Doubling 195 4.0

Air Conditioning 955 20.0

Power House 175 3.7

Lighting 55 1.2

Total 4,785 100

Process/Machines ModificationProcess/Machines ModificationEffective Utilization of Peak and Off Peak Hours Electricity ScheduleEffective Utilization of Peak and Off Peak Hours Electricity Schedule

WAPDA TOD Schedule

Season Peak (Avg. Rs.4.61/kWh

Off Peak(Avg. Rs. 3.62/kWh)

Dec to Feb 5:00 pm to 9:00 pm Remaining 20 hours

March to May 6:00 pm to 10:00 pm Remaining 20 hours

June to August 7:00 pm to 11:00 pm Remaining 20 hours

Sep to Nov 6:00 pm to 10:00 pm Remaining 20 hours

Process/Machines ModificationProcess/Machines ModificationEffective Utilization of Peak and Off Peak Hours Effective Utilization of Peak and Off Peak Hours Electricity ScheduleElectricity Schedule

Cleaning and Overhauling of Machines at Peak Hours

Electricity consumption (kWh/month) 189,037

Peak hours charges (Rs/month) 871,460

Off peak hours charges (Rs/month) 684,314

Saving per month 187,146

Process/Machines ModificationProcess/Machines Modification

When main units are stopped, auxiliary units like filters and air When main units are stopped, auxiliary units like filters and air

conditioning units should also be stoppedconditioning units should also be stopped

One set of machines are stopped but auxiliary units designed for One set of machines are stopped but auxiliary units designed for full full capacity remain in operationcapacity remain in operation

Machines run at partial loadsMachines run at partial loads

Machines must produce for the 75% of the total timeMachines must produce for the 75% of the total time

Process/Machines ModificationProcess/Machines ModificationOversized Motors/Efficient MotorsOversized Motors/Efficient Motors

Efficiency of oversized motors is not good – It needs frequent Efficiency of oversized motors is not good – It needs frequent monitoring of load (volt, ampere, power factor)monitoring of load (volt, ampere, power factor)

Oversized motors should be replaced with appropriate sized motors Oversized motors should be replaced with appropriate sized motors (Improved efficiency-Energy saving)(Improved efficiency-Energy saving)

Use of efficiency Class 1, Class 2 and Class 3 motorsUse of efficiency Class 1, Class 2 and Class 3 motors

Process/Machines ModificationProcess/Machines Modification(Air Conditioning) (Air Conditioning)

Air requirement is not known (velocity by anemometer , duct Air requirement is not known (velocity by anemometer , duct area)area)

Fan power Fan power αα (Air Flow (Air Flow33) i.e. By reducing air flow half, reduces fan ) i.e. By reducing air flow half, reduces fan power one eightpower one eight

Inverters can be placed on fans to change air flowInverters can be placed on fans to change air flow

FRP (Fiberglass Reinforced Plastic) are more energy efficientFRP (Fiberglass Reinforced Plastic) are more energy efficient

Process/Machines ModificationProcess/Machines Modification(Heating) (Heating)

Gas heating is cheaper than electric heatingGas heating is cheaper than electric heating

Hot exhaust gases of generators and compressors can be usedHot exhaust gases of generators and compressors can be used

Generator cooling water can be usedGenerator cooling water can be used

Steam can be usedSteam can be used

Infrared lamps can be usedInfrared lamps can be used