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, Air-
Compressing, 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 BEE Sponsored project
water in boilers 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)
Potential Power
Project cost Potential Power Potential carbon Savings in Rs
Savings in
Units (Rs. Savings in emissions in Lakhs/an
Units per
Lakhs) units/day tons/annum num
Annum
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

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 Monetary Savings Simple Payback Total Saving
Conservation (Rs.Lakh) Period (in years Potential of the
Measures cluster
(Rs.Lakh)
Solar Hot Water 0.60 3.3 90.00
System

Economizers (for 0.30 1.7 16.50

boilers)

Heat recovery 0.50 _ 50.00

from hot drained
water
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

~ POWER

Low pressure
Exhaust Steam
To Process

CO-GENERATION
BEE Sponsored project
23
 Cost benefit analysis
„ Capacity of the co-generation plant = 500 kW
„ No. of units generated/hr = 400 kWh
„ Steam generation = 5500 kg
„ Coal consumption = 760 kg
„ Coal cost (Rs.3.50/kg) = Rs.2660
„ Total fuel cost = Rs.2660
„ Monetary savings/hr = 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

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 350 Days
„ Quantity of hot water drained 85,000 liters/day
„ Average quantity per day for
conservative purpose (80%) 68,000 liters/day
„ Temperature of hot drain water 90o C
„ Quantity of heat can be recovered 27,20,000 kcal/day
„ Boiler efficiency 51%
„ Calorific value of fuel 5800 kcal/kg
„ Fuel savings 292 tons/annum
„ Fuel cost Rs. 3,500 per ton
Savings per annum Rs. 10.22 Lakh
Investment for tank, heat exchanger
and distribution system Rs.6.00 Lakh
Payback period 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