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By

Zenith Energy Services (P) LimitedHyderabad

Presentation on

Surat Textile ClusterSurat, Gujarat State

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Zenith Energy Services Pvt. Ltd. started Energy use and Technology Audits in Surat Cluster during the first week of June 2009.

Schedule of Implementation

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No. of units Covered for Energy use and Technology Audit

• Total No. of units in Surat Cluster - 410

• No. of units to be covered in the Cluster - 75 units

• As on date, The Energy use and Technology audit studies has been completed in 35 units

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Products Manufactured

• Synthetic Sarees

• Synthetic Dress Materials

• Fabric works

• Grey Cloth

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Process Flow Diagram

Contd.,

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Main Energy Forms used

• Electricity

• Fuels

Natural gas, Coal, Lignite and Biomass fuels

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Major Energy Consuming Process Equipments

• Jet machines• Drum machines• Stenters• Printing machines• Loop machines• Winding Machines• Reeling Machines

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Major Energy Consuming Equipments Utilities

• Boiler• Thermopac• Pumps• Air compressors • Blowers• Air conditioners • Lighting etc.

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Energy Scenario• Energy cost: 15 to 20% of the total production cost and varies

as per the products manufactured. • CMD: The connected load is less than or around 800 KVA in

the majority of these textile mills, • Steam demand: About 3 - 6 TPH depending on the production

capacity of the plant. • Electricity Consumption: The average electricity consumption

for a single plant ranges from 12.00 to 24.00 lakh units per annum

• Fuel Consumption: (coal, lignite or biomass) is 5000 to 7000 tons per annum. The natural gas consumption is about 10 to 15 lakh SCM.

• Energy Bill: The annual energy bill varies from Rs.250 to 400 lakhs for a single plant.

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Fuel Cost

Electricity• Rs. 5 per kWh

Bio mass Materials• Rs.2500 per ton

Coal• Rs.2500 per ton

Natural Gas• Rs. 11.5 per SCM

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Possible Areas of EC and EEEnergy Conservation

• Installing variable frequency drives for Jet machine pumps, ID and FD fans, Drum washers, oil circulation pumps, printing machines, air compressors will reduce energy consumption by about 20 to 25%

• Replace inefficient and local make pumps with new optimum sized and efficient pumps of KSB or Grundfos

• Recover sensible heat in drained hot water of Jet Machines and drum washers

• Install temperature control valves for all process equipments – Jet Machines, Drum machines, Stenters, Jigger machines etc

• Reduce hot air leaks from printing, stenter and loop machines• Improve boiler efficiency, replace faulty and mismatch traps,

avoid bypass of steam taps etc

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Energy Efficiency

• Replace new and energy efficient gas stenter machines and loop machines

• Install u tube jet machines with heat exchangers• Co- generation for heat and power generation

The monetary benefit is estimated as about Rs.25.00 to 40.00 lakhs per annum and the investment required for implementing the energy conservation measures is Rs.35.00 to 60.00 lakhs in various typical size of industries.

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• Though there is potential for replacing inefficient equipments like stenters and loop machines, the investment is high.

Energy Efficiency

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Issues and concerns for Implementation

• Involves high investment for technology change of various equipments and low returns

• Doesn’t have clarity on the savings achievable for the industry owners

• Interested in investment in low/medium cost energy efficiency measures, which have low payback periods of less than one year

Financial Issues

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Technical Issues

• Lack of awareness on technologies available in the market

• Rely on local equipment suppliers

• Unskilled manpower and doesn’t have consciousness on energy and its control mechanism and equipments

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Other Issues

• Lack of space for implementing the measures

• Interested in implementation of successful technologies of the cluster

• Shortage of gas for adopting fuel switch measures

• Production loss may be evident during implementation

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Case StudyAkashganga Processors Pvt. Ltd.

Products Manufactured

• Synthetic Sarees

• Synthetic Dress Materials

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Main Energy Forms used

• Electricity

• Natural Gas

• Coal

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Annual Energy Bill

Total: Rs. 289.67 lakhs

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Measures Identified

Heat Recovery from drained hot water of Jet Machines

• The monetary benefits are estimated as Rs. 12.23 lakhs per annum

• Reduces the fuel Consumption by 306 tons per annum

• The investment required for the insulated tank and heat exchanger is Rs. 6.00 lakhs

• Simple Pay back period is 6 months

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Replace Boiler Feed water pump

• Reduces the electricity consumption by 9300 kWh per annum

• Monetary savings is Rs.0.46 lakhs

• The investment required is Rs.0.50 lakhs

• Simple Payback period is 13 months

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Replace jet machine water circulation pumps

• Reduces the electricity consumption by 59,700 kWh

• Monetary savings is Rs.2.98 lakhs per annum

• The investment required for new pumps is Rs.5.00 lakhs

• Simple Payback period works out at 15 months

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Install Variable Frequency Drives for the Jet Machines

• Energy savings by implementing the measure is 53,200 kWh per annum

• Monetary savings is Rs. 2.7 lakhs per annum.

• The investment required for the VFD’s is Rs. 2.70 lakhs

• Simple Payback period works out at 12 months.

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Summary

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Tentative Schedule for Completion

• Dissemination Program : February 2010

• Energy use and Technology Audit will be completed by March 2010

• Cluster manual preparation by March 2010

• DPR Preparations from April 2010

• Local Service Providers Workshop June 2010

• Other programs as decided by BEE

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Thank You