Energy Conservation in Textile Industryodl.teriuniversity.ac.in/ren_en/pdf/Energy_Con/textile.pdfEnergy Conservation Measures / Activities of Raymond Ltd. Textile Division, Thane Sr

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Company Profile

Raymond is a market leader in the worsted suiting fabric of the textile industry in India. Raymond as a brand name is well recognised by the Indian consumer and created favourable image in the International market.

Company Profile (Contd.)

The plant is located in Thane (Maharashtra) and manufacturing one of the finest qualities of worsted suiting fabric. In the year 2001 – 2002 8.2 Million fabrics were produced and sale turnover was Rs.334 crores.

Company Profile (Contd.)

Unit has adopted the most modern technology and has also given utmost importance for Energy Conservation. Unit has received First Prize on National Energy Conservation Award for Year 2000, 2001 and 2002 given by Ministry of Power, Government of India.

Energy Consumption

With the implementation of various Energy Conservation measures as an ongoing practice, there is steady decline of specific energy consumption and cost. Last three years specific energy consumption figures are given below :

Energy Consumption

Description Unit 1999 - 2000 2000 - 2001 2001 - 2002

Electrical Energy

Thermal Energy

Total EnergyCost

Kwh/1000 picks

Kcal/1000 picks

Rs. Lakhs

2.26

3,615

2,164

2.22

3,421

2,170

2.05

3,031

2,002

Specific Thermal Energy Consumption

5272.39

4274.5

3615.263421.41

3031.69

2000

3000

4000

5000

KC

AL

/ '0

00 P

ICK

S

1997-98 1998-99 1999-00 2000-01 2001-02

YEAR

Specific Power Consumption

2.85

2.412.26 2.22

2.05

1.00

1.50

2.00

2.50

3.00

KW

H /

'000

PIC

KS

1997-98 1998-99 1999-00 2000-01 2001-02

YEAR

Energy Management Policy

Raymond is a market leader in the worsted suiting sector of the textile industry in India. Raymond as a brand name is well recognised by the Indian consumer and created favourable image in the International market.

Energy Management Policy (Contd.)

Raymond is committed to utilise various forms of energy in cost effective and efficient manner to conserve energy resources and to make cleaner environment for future generation.


To accomplish this company will :

�monitor and control the consumption of energy through effective energy information system and through periodic reviews.

�to carry out regular internal and external energy audits to identify areas for improvement.


�adopt energy conservation technology to enhance energy efficiency.

�create awareness among all employees for Energy Conservation Movement.


Company is committed to reduce Specific Energy Consumption by 1% every year for 5 years i.e. upto Year – 2007.


This will be achieved through dedicated teamwork, participation and commitment from employees at all levels.

(V. K. BHARTIA)PRESIDENT (TEXTILE DIVISION)

Energy Conservation Measures / Activities of Raymond Ltd. Textile Division, Thane

Sr.No. Description

Annual Savings

Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

A)

1)

WIHTOUT INVESTMENT :

Minimise idle running of auxiliary drive ofmachines (20 Nos.) by interlock with maindrive

0.76 Nil --

2) Frequency of steam trap checking has beenincreased thus reduction of fault trap quantityfrom 2% to 1%

4.8 Nil --

3) Minimisation of AC chiller and window ACrunning hours to reduce power consumption

1.06 Nil --


Sr.No Description

AnnualSavings

Rs. in Lakhs

Investment

Rs. inLakhs

Pay Backin Yrs

4) Regular checking of compressed air leakage invarious Departments by conducting leakage teston Mill holidays

2.25 Nil --

5) Use of natural lighting in the DyeingDepartment during day hours

0.45 Nil --TOTAL 9.32


Sr.No. Description

AnnualSavings

Rs. in Lakhs

Investment

Rs. in Lakhs

PayBackin Yrs

B)

1)

WITH INVESTMENT :

Addition of fuel additive in F.O. to improve Boiler’sperformance to reduce unburned (soot) loss

27.7 6.6 0.2

2) Installation of energy efficient motor for ring framemachine (2 Nos.) as efficiency remains constant even atpart load operation

0.27 0.48 1.73) Replacement of Aluminium blade Exhaust fans (30

Nos.) by energy efficient FRP blade fans

3.5 3.6 1.0


Sr.No. Description Annual Savings

Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

4) Replacement of slipring motors by superefficient SQ. induction motor for Aircompressor andChiller compressor 3.77 4.0 1.0

5) Installation of Digital Data Recording(DDR) to monitor feeder wise electricalparameter including power factor.Feeder wise power factor correction hasdone, thus improved the power factorupto 99% and reduction in maximumdemand 15.4 3.0 0.1


Sr.No. Description

AnnualSavings

Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

6) Recycle of process cooling water to conserve waterand reduction in power consumption of waterpumping and treatment

2.85 1.0 0.3

7) Recycle of process cooling water to conserve waterand reduction in power consumption of waterpumping and treatment

2.85 1.0 0.38)

a)

b)

Improvement in condensate recovery by 10% by :

Connecting more machines to condensate line

Minimisation of condensate contamination inCombing section through regular analysis ofcondensate sample of each Dyeing machine 3.4 1.0 0.2



Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

9)Regular checking of insulation condition ofBoiler, steam and thermic fluid line with non-contact laser thermometer and rectification

3.3 2.5 1.3

10)Regular checking of Boiler parameter i.e O2 ,CO2 and temperature of flue gas and tuning ofBoiler 3.8 0.6 0.1

11) Replacement of 80 Watts tubelights with samequanity of 40 Watts tubelight in warehouse 0.27 0.35 1.2



Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

12) Installations of variable speed drive forDyeing machine pumps to replaceinefficient throttle control

1.08 2.0 1.813) Replacement of electrical heater by

steam heater for preheating F.O. of 10TPH Boiler to substitute electricalenergy to heat energy

2.8 0.5 1.4



Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

14) Installation of high efficiency burner forThermic Fluid Heater as existing hashigh excess air and exit gastemperature 2.62 3.5 1.3

15) Use of steam heating system in StaffCanteen to replace LPG 0.88 0.50 0.5

16) Auto controller of AC system to optimisethe running hours of the plant atWarehouse 0.20 0.15 0.7



Rs. in Lakhs

Investment

Rs. in Lakhs

Pay Backin Yrs

17) Insulation pads with detachable buttons/ hooks are provided for flanges andvalves of steam pipelines of DyeingDepartment, which can be refitted afterthe maintenance of valves and flanges 0.46 0.10 0.2

Energy Conservation Measures under Execution

Sr.No. Description Investment Savings

A)

1)

WITHOUT INVESTMENT :

Stopping one 450 cfm compressor runningfor four hours per day by increasing thecapacity of existing compressor from 435cfm to 535 cfm by increasing the pulleysize of existing compressor

Nil 0.66 Lacs/ Annum

2) Replacement of D.C. Motor with A.C.Motor and Inverter in Kuster Mangle Nil 0.16 Lacs

3) Interlocking of Blowers of Lafer ShearingMachine (ENGG/EC/03/12) Nil 52,686/-


S r .N o

.D e s c r ip t io n In v e s tm e n t S a v in g s

4 ) Interlocking of Blowers ofSperretto Shearing M achine(ENGG/EC/03/13)

Nil 64,113/-

5 ) Interlocking of Blowers ofW oollen W inder ShearingM achine (ENGG/EC/03/14) Nil 36,778/-

6 ) Rem oval of extra tubelights in theloom area – Phase – II Nil 77,284/-

T O T AL 3,12,861/-


Sr.No Description Investment Savings

B)

7)

WITH INVESTMENT :

Replacement of old slip ringmotor with high efficiency(Efficiency – 95.2%) onCompressor –3)

1.9 Lacs 1.65 Lacs

8) Installation of timer on electricalheater for reducing the heatingtime of compressors of chillerplants

0.13 Lacs 0.27 Lacs



9) Installation of variable speeddrive on autowinding machines(2 Nos.)

2.0 Lacs /Machine

1.5 Lacs /Machines

10) Installation of Sonic Soot Blowerin 10 T/Hr. Boiler for sootremoval in smoke tubes 1.90 Lacs 4.7 Lacs

11) High Efficiency CentrifugalBlower for Spinning Air Washer(ENGG/EC/03/02) 5.0 Lacs 4.9 Lacs



12) Lowering the Pump Suction Height onReservoir (ENGG/EC/03/04) 10,000/- 19,152/-

13) Rearrangement of Light in MechanicalWorkshop (ENGG/EC/03/05)

9,000/- 29,138/-

14) Separate switch Arrangement for LightFitting in Warping Area Passage (Phase– I) (ENGG/EC/03/07)

18,400/- 38,851/-


Sr.No. Descr iption Investment Savings

15) Separate switch Arrangement forLight Fitting in Warping AreaPassage (Phase – II)(ENGG/EC/03/08) 13,110/- 25,498/-

16) Removal of Extra Tubelights inLoom Area (ENGG/EC/03/09)Phase – I 240/- 25,771/-

17) Changing of Motor connectionfrom Delta to Star(ENGG/EC/03/10)

10,565/- 36,977/-


Sr.No

.Description Investment Savings

18) Replacement of 2 Nos. ofAluminium Casting Fan withFRD of Spinning Department(ENGG/EC/03/11

61870/- 60,480/-

19) Increase of Pump Efficiency ofVarious Pumps by ceramicCoating

62,120/- 2,31,480/-

20) Replacement of Schrge motor bySuper Efficient Induction motoron BM-14 (Ist ) 2.0 Lacs 1.36 Lacs



21) Loading 40 H.P. Pump Suction Height onthe reservoir 15,000/- 90,804/-

TOTAL 14,48,305/- 16,14,671/-

ORGANISATION CHART

WORKS DIRECTOR

INSTRUMENTATION DEPARTMENT PRODUCTION

DEPARMENTAL HEADS

MECHANICAL GENERAL MANAGER DEPARTMENT ENGINEERING

ELECTRICAL DEPARTMENT

Functioning of Energy Conservation Cell

• Daily monitoring of power consumption.• Daily monitoring of fuel consumption.• Daily monitoring of water consumption.• Conducting quarterly Energy Meeting to have

progress of implementation of energy conservation measures of each unit.

• Conducting field study to identify the potential areas for energy conservation.

• Collection of data on energy consumption, of other plants for Bench Marking.


• Preparation of Techno-economic feasibility reports on the basis of field study under medium and long-term energy conservation projects.

• Preparation of proposals for capital budget approval under energy conservation project.

• Fixing of yearly target of energy consumption for each section.

• Following strategies are followed to implement the energy conservation projects after obtaining approval from higher authorities.

• Floating the inquiries to obtain the offers from the parties and finalising the orders.


• The responsibility for implementation job as allocated to the concerned department i.e. Mechanical, Electrical and Instrumentation depending on the nature of the job.

• Monitoring of Energy consumption after implementation of various measures to find out the actual savings vis a vis anticipated savings.

• Continuous review of small group activities proposals for implementation.

Small Group Activities at Thane (Textile Division)

• We have found 8 small group activities comprising of persons from grass root level like machine operators, fitters, etc. The group has been formed sectionwise keeping in mind different production areas of the mill. The number of members in each SGA consist of managers, engineers, clerks, fitters, operators as per the requirement for smooth functioning of group. These group identify energy conservation measures into following basis :


• Measures requiring zero investment i.e. fine tuning of either process parameter or change in procedure.

• Measures requiring some investment and payback is within 2 years.

• Measures requiring capital investment on payback and within 2 – 3 years. Our SGA group implements the above (a) & (b) measures and implements within a short span of time as it doesn’t require much investment.


• Whereas for measures requiring capital investments are forwarded to the concerned sanctioned authorities for approval.and once the approval is given, these proposals goes to the concerned department for implementation. We are very grateful to Mr. K. K. Chakarvarti(Energy Economist), Ministry of Power, for showing the ways of implementing energy conservation measures through the root of small group activity which we started from the month of February, 2003. You can very well see that lot of proposals have been implemented with either no investment or from less investment.

Futuristic Planning of Energy Conservation Measures

�Co-generation based Captive Power Plant.

�Installation of variable speed drives for various production machines.

�Heat recovery from hot effluent to generate hot water for Boiler and process.

Futuristic Planning of Energy Conservation Measures (Contd.)

�Auto Process Control System for Dyeing machines.

�Replacement of old inefficient water pump with efficient pump.

�Installation of variable speed drives of air compressor and chiller plant compressor.

Futuristic Planning of Energy Conservation Measures (Contd.)

�Auto Control System for Cooling Tower fans.

�Heat recovery from exhaust gas of Thermic fluid heaters.

�Use of Solar energy for various heating applications.

�Use of Natural draft Cooling Towers instead of Conventional one.

THANKTHANK

YOUYOU

Documents

Energy Conservation in Textile Industryodl.teriuniversity.ac.in/ren_en/pdf/Energy_Con/textile.pdfEnergy Conservation Measures / Activities of Raymond Ltd. Textile Division, Thane Sr