Chapter 4

Reference plants

Many plants.

Reference literature

[180, Spain, 2001], [204, L. Bettens, 2000].

4.8 Finishing
4.8.1 Minimisation of energy consumption of stenter frames

Description

Stenters are mainly used in textile finishing for heat-setting, drying, thermosol processes and
finishing. It can be roughly estimated that, in fabric finishing, each textile substrate is treated on
average 2.5 times in a stenter.

Energy savings in stenters can be achieved by applying the following techniques.

A) Optimising exhaust airflow through the oven

The main energy requirements for a stenter are for air heating and evaporation. It is therefore
fundamental that the fabric moisture content should be minimised before the fabric enters the
stenter and that exhaust airflow within the oven is reduced.

Water content on the incoming fabric can be minimised using mechanical dewatering equipment
such as vacuum extraction systems, optimised squeezing rollers, etc. (the latter is less efficient,
but less energy consuming). Up to 15 % energy savings in the stenter (depending on the type of
substrate) can be obtained if moisture content of the fabric is reduced from 60 % to 50 % before
it enters the stenter.

Exhaust airflow optimisation is another determinant factor. Many stenters are still poorly
controlled, relying on manual exhaust adjustment and operator estimation of fabric dryness. For
optimum performance, exhaust humidity should be maintained between 0.1 and 0.15 kg
water/kg dry air. It is not unusual to find stenters with exhaust humidity of only 0.05 kg
water/kg dry air, indicating that the exhaust volume is too high and excessive energy is being
used to heat air [146, Energy Efficiency Office UK, 1997]. Energy consumption for air heating
can reach up to 60 % of the total energy requirement, if airflow is not monitored [185, Comm.,
2001].

Equipment is available (variable-speed fans) which will automatically adjust exhaust airflow
according to moisture content of the exhaust air or according to moisture content or temperature
of the fabric after the process. A reduction of fresh air consumption from 10 kg fresh air/kg
textile to 5 kg fresh air/kg textile results in 57 % energy saving [179, UBA, 2001].

B) Heat recovery

Exhaust heat recovery can be achieved by using air-to-water heat exchangers. Up to 70 % of

energy can be saved. Hot water can be used in dyeing. Electrostatic filtration for off-gas
cleaning can optionally be installed. Retrofitting is possible.

If hot water is not required, an air-to-air heat exchanger can be used. Efficiencies are generally
50 to 60 % ([146, Energy Efficiency Office UK, 1997]). Approximately 30 % savings in energy

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can be achieved [179, UBA, 2001]. An aqueous scrubber alone or with subsequent electrostatic
filtration can optionally be installed for off-gas cleaning.

C) Insulation

Proper insulation of stenter encasement reduces heat losses to a considerable extent. Savings in
energy consumption of 20 % can be achieved if the insulation thickness is increased from 120 to
150 mm (provided that the same insulation material is used).

D) Heating systems

Direct gas firing is reported to be both clean and cheap. When it was first introduced there was
concern that oxides of nitrogen, formed by exposure of air to combustion chamber temperature,
would cause fabric yellowing or partial bleaching of dyes. This concern has since been shown to
be unjustified [146, Energy Efficiency Office UK, 1997].

However, other sources also show the advantages of new (recently developed) indirect gas
firing systems. By means of a flue gas/air heat exchanger the heat generated by the burner flame
is directly transferred to the circulating air in the stenter (“Monforts, Textilveredlung 11/12,
2001, p.38”). This system has higher efficiency than conventional indirect heating systems
using mainly heating oil. Reactions of off-gas compounds with emissions from the textile
materials and auxiliaries (especially generation of formaldehyde) are avoided.

E) Burner technology

With optimised firing systems and sufficient maintenance of burners in directly heated stenters,
the methane emissions can be minimised. A typical range for an optimised burner is 10 - 15 g
methane (calculated as organic carbon)/h, but it has to be taken into account that methane
emissions from burners are strongly linked with actual burner capacity.

Stenters should receive general maintenance by specialised companies at regular intervals.

There should also be routine checking of the burner air inlet for blocking by lint or oil, cleaning
of pipework to remove precipitates and adjusting of burners by specialists.

F) Miscellaneous techniques

With optimised nozzles and air guidance systems, energy consumption can be reduced,
especially if nozzle systems are installed that can be adjusted to the width of the fabric.

Main achieved environmental benefits

Savings in energy consumption and therefore minimisation of emissions associated with energy
production are the main environmental advantages.

Data about achievable energy savings are already indicated for some of the presented
techniques. Obviously, for existing plants, the potential for reductions will vary according to the
existing technology and energy management policy in the company.

Operational data

Minimising energy consumption in the stenters, especially if heat recovery systems are
installed, requires adequate maintenance (cleaning of the heat exchanger and stenter machinery,
checking of control/monitoring devices, adjusting of burners etc.).

Proper scheduling in finishing minimises machine stops and heating-up/cooling-down steps and
is therefore a prerequisite for energy saving.

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Heat recovery systems are often combined with an aqueous scrubber or electrostatic filtration
systems or a combination of these techniques.

Condensed substances (mainly preparation oils) from heat recovery systems have to be collected
separately.

Cross-media effects

None believed likely.

Applicability

All described techniques are applicable to new installations. For existing equipment, the
applicability is in some cases limited. For example, improving stenter insulation (see Option C)
is not always practicable, although on some older machines, it may be cost-effective to insulate
the roof panels. Existing stenters cannot be retrofitted with air-to-air heat exchangers.

Economics

Payback data for heat recovery systems (both air/water and air/air systems) are illustrated in
Table 4.35 for drying and heat-setting processes. Information is based on the following
reference data [179, UBA, 2001]:
· heat recovery system: counter-flow pipes
· drying temperature: 130°C
· heat setting: 190°C
· off-gas volume flow: 15000 m³/h
· off-gas moisture content (drying): 70 g/m³
· off-gas moisture content (heat-setting): 40 g/m³
· T of the fresh water (before heat recovery): 15°C
· efficiency: 70 %
· heating value of the gas 9.3 kWh/m³
· cost of the gas: 0.25 euros/m³
· maintenance cost: 1000 euros/yr
· interest rate: 6%

1-shift/day 2-shift/day 3-shift/day

Process Savings Pay-back Savings Pay-back Savings Pay-back

(euros) period (yr) (euros) period (yr) (euros) period (yr)
Air/water Drying 32050 5.7 64150 2.6 96150 1.7

Fresh water Heat-setting 34450 5.4 68900 2.4 103350 1.5

T: 15 °C
Air/water Drying 18050 12.6 36100 5.9 54150 3.3

Fresh water Heat-setting 23350 8.6 46700 3.7 70050 2.4

T: 40 °C
Air/air Drying 8000 > 20 16000 15.6 24000 8.5

Fresh air Heat-setting 11000 > 20 22000 9.6 33000 6.6

temp.20 °C
Source: [179, UBA, 2001]
Table 4.35: Return on investment for different processes (textiles drying and heat setting), heat
recovery systems (air/water and air/air) and number of shifts per day

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The above information does not consider the installation of other measures such as fabric
moisture control and exhaust humidity control. If these systems are installed, according to some
sources heat recovery may not be cost-effective [146, Energy Efficiency Office UK, 1997].

Driving force for implementation

Minimisation of energy consumption (and therefore costs) is the main reason to retrofit
optimised stenter technology.

Reference plants

The described technologies are in use in many finishing mills in Europe and worldwide. The
indirect heating system based on flue-gas/air exchanger is currently due to be installed in several
finishing plants.

Reference literature

[146, Energy Efficiency Office UK, 1997], [179, UBA, 2001], [185, Comm., 2001].

4.8.2 Formaldehyde-free or formaldehyde-poor easy-care finishing

agents

Description

Easy-care finishing is mainly carried out on cellulosic fibres and their blends in order to
increase the crease recovery and/or dimensional stability of the fabrics (see Sections 2.9.2.1 and
8.8.1).

Easy-care finishing agents are mainly compounds synthesised from urea, melamine, cyclic urea
derivatives and formaldehyde. Cross-linking agents (reactive groups) are composed of free or
etherificated N-methylol groups.

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