Beruflich Dokumente
Kultur Dokumente
(PROCESSING SECTOR)
Supported by
RENEWABLE ENERGY & ENERGY EFFICIENCY
PROGRAMME (REEE)
DISCLAIMER
The Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH is
implementing the Renewable Energy & Energy Efficiency (REEE) Programme
on the basis of a commission from the German Federal Ministry for Economic
Cooperation and Development (BMZ). On behalf of Government of Pakistan,
Small & Medium Enterprise Development Authority (SMEDA) & National
Productivity Organization (NPO) are implementing partners in this project.
The opinions and analyses expressed in this report do not necessarily reflect
the views and official policies of the REEE Programme.
This report is based on the findings of energy efficiency audits and will be
updated on a regular basis to include more suitable measures identified in
additional energy efficiency audits.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008
Renewable Energy & Energy Efficiency Programme (REEE)
10 FLAME ADJUSTABLE SINGEING MACHINE...................................................................... 18
10.1 PROBLEM .............................................................................................................................. 18
10.2 PROPOSED ACTIONS .............................................................................................................. 18
11 INSTALLATION OF HEAT EXCHANGER ON HOT WASTEWATER ............................... 19
11.1 PROBLEM .............................................................................................................................. 19
11.2 PROPOSED ACTIONS .............................................................................................................. 19
12 IMPLEMENTATION OF COUNTER CURRENT WASHING AT MERCERIZATION /
SOAPER /.BLEACHING PLANT....................................................................................................... 20
12.1 PROBLEM .............................................................................................................................. 20
12.2 PROPOSED ACTIONS .............................................................................................................. 20
13 REUSE OF COOLING WATER................................................................................................ 21
13.1 PROBLEM .............................................................................................................................. 21
13.2 PROPOSED ACTIONS .............................................................................................................. 21
14 INSTALLATION OF TEMPERATURE GAUGES/INDICATORS ON HOT MACHINES... 22
14.1 PROBLEM .............................................................................................................................. 22
14.2 PROPOSED ACTIONS .............................................................................................................. 22
15 INSTALLATION OF WATER FLOW METERS ON WATER INLETS................................ 23
15.1 PROBLEM .............................................................................................................................. 23
15.2 PROPOSED ACTIONS .............................................................................................................. 23
16 ELECTRICAL DISTRIBUTION SYSTEM .............................................................................. 24
16.1 PROBLEM .............................................................................................................................. 24
16.2 PROPOSED ACTIONS .............................................................................................................. 25
17 COMPRESSED AIR SYSTEM .................................................................................................. 29
17.1 PROBLEM .............................................................................................................................. 29
17.2 PROPOSED ACTIONS .............................................................................................................. 30
18 LIGHTING.................................................................................................................................. 32
18.1 PROBLEM .............................................................................................................................. 32
18.2 PROPOSED ACTIONS .............................................................................................................. 32
19 REUSE OF CLEAN HOT WATER STREAM OF JETS.......................................................... 34
19.1 PROBLEM .............................................................................................................................. 34
19.2 PROPOSED ACTIONS .............................................................................................................. 34
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008
Renewable Energy & Energy Efficiency Programme (REEE)
INTRODUCTION
BACKGROUND
The Small and Medium Enterprise Development Authority (SMEDA) as well as
the National Productivity Organization (NPO) have been supported by the
Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH to
introduce Energy Efficiency in the Textile Industry. This initiative helps the textile
sector address energy losses and related productivity, quality losses.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 1
Renewable Energy & Energy Efficiency Programme (REEE)
Reducing the need for investment in newer power plants and import of
energy
Reducing the dependence on conventional resources like oil and natural
gas etc.
Reducing emissions of air pollutants in most cases
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Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 2
Renewable Energy & Energy Efficiency Programme (REEE)
ENERGY SAVING POTENTIALS
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Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 3
Renewable Energy & Energy Efficiency Programme (REEE)
2 BETTER PROCESS CONTROL
2.1 PROBLEM
Normally workers are habitual of carrying out textile processing with
conventional techniques, they do not like to change it and consider hard to
adopt better practices or any thing different from their natural working style.
Due to lack of education and training, they are unable to understand the
chemistry behind each process. They can not understand that these chemical
processes are based on certain process parameters such as temperature,
concentration and pH. Slight variation in these parameters, can result into either
excess use of chemicals or deterioration of fabric quality, in most of the cases.
In the absence of the feeling of their importance among workers, they consider
controlling, monitoring and recording them in daily log sheets useless.
Singeing
Record information of the grey fabric received from grey fabric store, including
its type, length, width and GSM (gram per square meter).
Record production of the singed fabric with all of the fabric parameters
mentioned above parameters.
Desizing
Optimize desizing process recipe on the basis of type and quantity of sizing
chemicals present on the fabric
Record quantities of chemicals like enzyme, salt and detergents used in the
desizing bath
Control and record temperature and pH of the desizing bath
Record production of the sized fabric with all of the fabric parameters
mentioned above.
Scouring
Optimize scouring process recipe on the basis of type and quantity of sizing
chemicals present on the fabric
Record quantities of chemicals like caustic soda, sodium carbonate (soda ash),
,detergents, and sodium silicate used in the scouring bath
Control and record temperature of scouring chemical solution and bath (and
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 4
Renewable Energy & Energy Efficiency Programme (REEE)
pressure in case of scouring in kier)
Record production of the scoured fabric with all of the fabric parameters
mentioned above
Bleaching
Optimize bleaching process recipe according to the degree of whiteness
required (for darker shades, bleaching may be omitted).
Record quantities of chemicals like bleaching agent (NaOCl), used in the
bleaching bath
Control and record temperature of the bleaching bath
Record production of bleached fabric with all the fabric parameters mentioned
above
Neutralization
Monitor and record pH of the fabric before neutralization
Record quantity of acid used for neutralization
Monitor and record pH after neutralization
Record production of neutralized fabric with all the fabric parameters mentioned
above
Mercerization
Control and record temperature and concentration of caustic soda bath
Control and record percent stretch of fabric
Record quantity of caustic soda used for mercerization
Record production of mercerized fabric with all the fabric parameters mentioned
above
Dyeing
Record quantities of chemicals like dye, salts, levelers, caustic soda, sodium
carbonate, acids etc.
Temperature and pH of dye bath in each step
Control and record pressure of the dye machine in case of jets
Record production of the dyed fabric for each type of dye with all the fabric
parameters mentioned above.
Boiler
Record daily water and gas consumption in the boiler section
Record daily steam consumption (if steam flow meter is installed)
Monitor and record TDS, pH and hardness of the boiler feed water
Monitor and record TDS of the blow down
Monitor and record TDS, pH and hardness of the returned steam condensate
Record hardness at which regeneration of water softener is carried out with the
frequency and quantity of salt used in it (if water softener is installed)
Blow Down should be on the basis of Water TDS
Date
January, 2008 5
Renewable Energy & Energy Efficiency Programme (REEE)
Some of the common problems faced by mills in the distribution of steam are
briefly described
Inadequate capacity of steam generation due to deterioration in boiler capacity
or due to expansion of processing without a matching expansion in the boiler
plant
Large pressure fluctuations at the machine due to use of too small a pipe line
Improper design of branch piping particularly after pressure reducers
Inadequate draining of the lines
Poor lagging
Live steam leakages
Inadequate pressure at machines due to a large number of machines being
trapped from the same branch line
Uneven distribution of steam load on different mains or branches
Absence of sufficient margin for possible future expansion
Wrong inclination of steam mains, branches and other pipe lines
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January, 2008 6
Renewable Energy & Energy Efficiency Programme (REEE)
the presence of sodium sulphate or sodium nitrate in adequate concentrations.
3 INSULATION OF BARE HOT SURFACES
3.1 PROBLEM
Energy is a major resources of the textile industry, for which mill owners have
become more conscious about its saving due to day by day rise in its prices.
There are a number of reasons due to which energy losses occur. Uncovering of
hot fluid carrying pipelines and machines is one of these reasons. There are
different locations in the production hall where either proper insulation is not
provided for the heat conservation purposes or present insulation has been
damaged and not been repaired.
Besides energy losses, uncovered hot surfaces can cause skin burn in
case these were touched unintentionally by the workers and visitors. The
recommended safe touch temperature range is 55-65oC.
After selecting insulator, its optimum thickness is evaluated because cost of the
insulation depends largely on its thickness. In case, thickness is inappropriate,
heat losses are not reduced and heat energy is lost to the environment by
conduction through insulator. At a certain thickness, called critical thickness,
heat losses start decreasing with the increase of thickness. Thickness, above
the critical thickness, is the optimum thickness.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 7
Renewable Energy & Energy Efficiency Programme (REEE)
4 REUSE OF STEAM CONDENSATE
4.1 PROBLEM
Steam is an important source of supplying thermal energy to the process.
Steam is either employed directly or indirectly. Direct usage typically occurs in
the form of steam being injected into water or injected on the fabric. Direct
usage has the highest possible heat transfer efficiency. Indirect usage requires
additional heat exchanges – thus reducing the heat transfer efficiency. But this
method has the advantage that the condensed steam (condensate) which has
transferred its energy can be used again.
Steam condensate is a pure and hot water stream, which can be reused for
boiler feed water and for the formulation of dye and printing solution. Most of the
units waste this important water stream due to non existence of its proper
collection and reuse arrangement.
Following are the sources from where the steam condensate is generated and
ultimately wasted as wastewater stream:
Calenders' heaters
Drum dryers
Kiers heaters
Jets' heaters
Comfit heaters
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 8
Renewable Energy & Energy Efficiency Programme (REEE)
5 UPKEEP OF STEAM TRAPS
5.1 PROBLEM
Steam traps are the important part of the steam distribution system. In closed
circuit, steam after loosing its latent heat, becomes liquid called steam
condensate, which has to be removed from the system. In case, steam
condensate is not removed, steam system will not work due to its accumulation
in the system. As both streams i.e. steam and condensate, are present in the
lines, therefore such type of equipment is required which only removes
condensate but not the steam. Steam traps are fitted in the steam lines to
remove only steam condensate, air and non-condensable gases, not the steam.
In case these traps do not work properly due to some reasons or become
damaged, they allow both streams of steam and condensate to escape from the
system freely. Wastage of steam is not only the economic loss but also makes
working environment hot and humid.
In most of the textile industries, steam traps are found malfunctioning. Steam
leakage, along with the condensate is a regular feature in the production hall.
Maintenance crew does not have realization that these malfunctioning traps
cause huge energy losses. Most of these traps were fitted in the system, at the
start but not replaced or repaired after they became damaged during operation
as nobody consider it important entity.
Maintenance staff is advised to examine them regularly and take care of their
proper repair, maintenance and replacement, if required, on regular basis. A
variety of steam traps are available in the market. Some are very expensive with
long life whereas the others are cheap and get damaged soon.
Thus steam traps selection is important for their uninterrupted operation. Brief
description of different steam traps is given in the following section.
Orifice
They contain an adjustable orifice in the body which continually discharges
condensate. They are self regulating. When the rate of condensation
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Best Practices Report (Version 1.0) in Processing Sector
Date
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Renewable Energy & Energy Efficiency Programme (REEE)
decreases, the condensate temperature increases due to the presence of
steam. It causes throttling in the orifice and reduces capacity due to steam
flashing on the downstream side. An increased load decreases flashing and the
orifice capacity becomes greater.
There is possibility that on light loads, these traps pass live stream. They can
become clogged due to the build up of particulates in the orifice. These
impurities can cause erosion and damage the orifice size, causing escape of
steam.
Inverted Bucket
They have a bucket that rises or falls as steam and/or condensate enters the
trap body. When steam is in the body, the bucket rises and closes the valve.
When condensate enters, the bucket sinks down, and opens the valve and
allows the condensate to drain. These traps are ideally suited for water hammer
conditions.
Thermodynamic
They have a disc that rises and falls depending on the variations in pressure
between steam and condensate. Steam tends to keep the disc down or closed.
When condensate builds up, it reduces the pressure in the upper chamber and
allows the disc to move up for condensate discharge.
This trap is good where steam pressures remain constant. It can handle
superheat and water hammer but is not recommended for process, since it has
a tendency to air bind and does not handle pressure fluctuations well.
Two of the most common causes of trap failure are over sizing and dirt. Over
sizing causes traps to work too hard. In some cases this can result in blowing of
live steam. Dirt is always created in the steam system. Excessive build up can
cause plugging or prevent a valve from closing. Dirt is generally produced from
pipe scale or from over treating of chemicals in the boiler. Mostly inverted bucket
types are used in the textile mills.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 10
Renewable Energy & Energy Efficiency Programme (REEE)
6 INSTALLATION OF ECONOMIZER ON BOILER FLUE
GAS
6.1 PROBLEM
o
Flue gas discharged in the atmosphere at a temperature of 180-200 C from the
steam boiler contains substantial thermal energy, which is being lost in the
atmosphere presently.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 11
Renewable Energy & Energy Efficiency Programme (REEE)
7 MEASUREMENT OF BOILER EFFICIENCY
7.1 PROBLEM
There is much more worry about the efficiency of the steam boilers, mainly
because of the day by day rise in the energy price. The more efficient the boiler
is, the lesser its fuel consumption will be.
Industry should install water, steam and gas (where gas is the fuel) flow meters
to measure consumption of these utilities and consequently enable
measurements of boiler performance or efficiency. Ignorance of boiler
performance monitoring and evaluation is a serious concern with respect to
energy conservation and environmental pollution.
Parameter
Temperature of flue gas
Sulfur dioxide (SO2)
Nitrogen Oxides-NOx (NO2+NO)
Nitric Oxide (NO)
Nitrogen dioxide (NO2)
Carbon monoxide (CO)
Carbon dioxide (CO2)
For steam monitoring, steam flow meter can be installed at the boiler. However,
if installation of steam meters is not possible due to their high price, then water
and gas meters can be used to measure boiler efficiency, which are relatively
cheap. One cubic meter of water and 90 m3 of natural gas at 80% combustion
1
A system for retrofitting burners with lambada control is offered under www.burnermax.com
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Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 12
Renewable Energy & Energy Efficiency Programme (REEE)
efficiency generate about one ton of steam at 150 Psig.
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Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 13
Renewable Energy & Energy Efficiency Programme (REEE)
8 ENERGY LOSS THROUGH BLOW DOWN
8.1 PROBLEM
Blow down discharged in the environment at a very high temperature from the
steam boiler contains substantial thermal energy, which is normally lost in the
atmosphere.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 14
Renewable Energy & Energy Efficiency Programme (REEE)
9 INSTALLATION OF WATER SOFTENER/REVERSE
OSMOSIS (RO) FOR PROCESS AND BOILER FEED
WATER
9.1 PROBLEM
Generally the groundwater is the source for process and boiler feed water in the
textile mills. This water contains calcium, magnesium and other metals which
have certain impacts in textile processing in terms of additional water and
chemical consumption and product quality deterioration. High mineral laden
water also leads towards additional energy requirements. The use of such water
also results into scale formation in the machines and conveyance system which
affects their life and efficiency.
In case of boiler, scale formation on the heating surfaces affects the boiler
efficiency and may lead to damages of the boiler tubes. To cope with the
situation, boiler water conditioning chemicals are dosed in heavy quantities,
which is expensive in terms that salt deposition increases at the bottom of boiler
body and removed ultimately from the system through blow downs. Excessive
blow downs are one of the sources from where thermal energy is lost
extensively.
Desizing
Scouring
Bleaching
Mercerization
Dyeing
Printing
Water Softener
Ion exchange removes unwanted ions from the raw water by transferring them
to a solid material, called an ion exchanger, which accepts them while giving
back an equivalent number of a desirable species stored in it. The most
commercial ion exchangers are synthetic plastic materials, such as
copolymers of styrene and divinyl benzene. Cat ion exchanger (used to
exchange cat ions of calcium and magnesium with sodium) called sodium
zeolite is generally used. The ion exchanger has a limited capacity for storage
Title
Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 15
Renewable Energy & Energy Efficiency Programme (REEE)
of ions, called its exchange capacity. Due to its limited capacity, ion exchanger
eventually becomes depleted
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Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 16
Renewable Energy & Energy Efficiency Programme (REEE)
of its desirable ions and saturated with unwanted ions. It is then washed with a
strong regenerating solution containing the desirable species of ions (sodium
chloride salt solution), and these then replace the accumulated undesirable
ions, returning the exchange material to a usable condition i.e. the unwanted
calcium and magnesium ions on the surface of exchanger are
washed/removed by exchanging themselves with the sodium ion of salt solution
during regeneration process.
Zeolite softening is the oldest and the simplest of the ion exchange process. It
removes hardness from water, including iron and manganese, if these
constituents can be kept in the reduced ionic form.
The equipment design is simple consisting of a steel shell holding the ion
exchange bed and provided with piping and valves to permit the essential
operations of softening, backwash, brining and rinsing. If storage capacity is
provided for softened water, a single unit may be adequate for the plant needs.
In larger plants, it is common to have more than one unit, so that one can be
taken out of service for regeneration without interrupting the flow of soft water.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 17
Renewable Energy & Energy Efficiency Programme (REEE)
10 FLAME ADJUSTABLE SINGEING MACHINE
10.1 PROBLEM
Most of the textile industries have installed singeing machines with burners fixed
to certain length. Grey fabric subjected to singeing treatment varies in width
(from 1 to 2 meter). Fabric of any width, whether wide or small, has to pass over
the full width of burners. This is due to the fact that the burners' width is fixed
and can not be adjusted according to the width of the subjected fabric. This is
one of the areas where substantial energy is lost.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 18
Renewable Energy & Energy Efficiency Programme (REEE)
11 INSTALLATION OF HEAT EXCHANGER ON HOT
WASTEWATER
11.1 PROBLEM
Extensive hot washes are carried out in the textile industries to wash impurities,
undesired chemicals and unfixed dyes and pigments. Hot wastewater from
these washes contains substantial amounts of thermal energy which costs
millions of rupees per year.
For the effective heat recovery, following are the suitable waste streams:
Heat energy of the above hot washes can be recovered by installing shell and
tube heat exchanger. For the implementation of this option, hot washes are first
collected in a small covered storage tank. It is then pumped into the heat
exchanger while passing through the strainer, in the tube side, whereas fresh
water, which will be used as hot washing water, flows in the shell side. Fresh
water is heated and used in the washings. Under such arrangement less
quantity of steam will be required to heat up the washing water up to the
required temperature as it is already pre-heated.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 19
Renewable Energy & Energy Efficiency Programme (REEE)
12 IMPLEMENTATION OF COUNTER CURRENT
WASHING AT MERCERIZATION / SOAPER
/.BLEACHING PLANT
12.1 PROBLEM
Post mercerization/bleaching/soaper washes, which are in different
numbers, consume large quantity of water and steam. Normally washing
pattern is such that each wash box acts as an individual chamber where
water and steam is supplied at one side and hot wastewater is discharged
through overflow pipe from the other side.
In the counter current washing, water flow is designed in such a way that the
clean fabric makes contact with the clean water and dirty fabric with the dirty
water. Fresh clean water is supplied in the last box from where clean fabric
comes out after washing. This water, from the last box, overflows to the next
box and so on. The overflow pipes are arranged in such a way that the overflow
pipe at the last box is placed at the highest level whereas it is at the lowest level
at the first box. This difference in levels of overflow pipes establishes gradient
by which water flows from the last box to the first. From the first box, water is
discharged as wastewater. In this way, wastewater of one box is used as feed
water for the next and so on. In case of hot wastewater, its energy is utilized in
washing, too.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 20
Renewable Energy & Energy Efficiency Programme (REEE)
13 REUSE OF COOLING WATER
13.1 PROBLEM
Fresh water is used in machines and pumps to cool mechanical seals and other
moving parts in order to avoid overheating. Typical examples of this type of
machinery are:
Compressors
Thermo oil boiler pumps
Ammonia chillers
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 21
Renewable Energy & Energy Efficiency Programme (REEE)
14 INSTALLATION OF TEMPERATURE GAUGES/INDICATORS
ON HOT MACHINES
14.1 PROBLEM
Energy monitoring is the first step in the energy management. In most of the
industries, no actions have been taken to reduce energy losses by the
management due to a lack of awareness about the energy conservation and its
benefits. A number of areas have been identified where energy is not being
monitored. Temperature is not monitored for the hot washing baths such as
desizing, bleaching, scouring and dyeing processes. Workers keep on injecting
steam in the baths to heat up water, even after attaining the required
temperature. Since there is no temperature indication and automatic shut off
valves for steam, temperature is being controlled by visual judgment. The lack
of energy monitoring results in energy wastage and its excess and unnecessary
use at various levels of production processes.
Title
Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 22
Renewable Energy & Energy Efficiency Programme (REEE)
15 INSTALLATION OF WATER FLOW METERS ON
WATER INLETS
15.1 PROBLEM
In general, water is abundantly available and easily accessible in Pakistan. No
direct cost is borne for it. Workers, in general, consider this commodity as cheap
and invaluable. Even management is not much concerned about the excessive
use of water in different processes, especially in washing. Mostly, these washes
are continuous, where water is supplied at one end and discharged from the
other. Excess use of water is not only the direct loss of natural resource but also
it results into excess use of chemicals in the process vessels because most of
the textile chemicals are fed in the process vessels on the basis of water
quantity. If more chemicals are added in the process vessels, there will be more
pollution in the washing wastewater at the end.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 23
Renewable Energy & Energy Efficiency Programme (REEE)
16 ELECTRICAL DISTRIBUTION SYSTEM
16.1 PROBLEM
Proper electric distribution systems are important for the reduction of energy
losses. The electrical power distribution system, from the source to utilization
points, consists of electric lines of varying sizes, switches and circuit breakers,
transformers and protective equipment. The voltage in an electric circuit will
drop in proportion to the circuit resistance. Resistance varies with wire size,
temperature and metallic material. When conductor losses increase, the current
necessary to deliver a given amount of power increases at any point in the
circuit, as power derives from the product of the voltage and current. This
principle applies likewise to switches, circuit breakers and protective equipment.
Generally the electrical distribution system losses are due to voltage unbalance,
over and under voltage, low power factor, undersized conductors, leakage to
ground, and poor connections. Losses due to poor connections represent one
third of the total loses.
Electrical Motors
After electrical distribution system, electrical motors play an important role in the
energy saving. The electric motors are the main consumers of the electricity.
More than 90% of the electricity is consumed by the electric motors. Major
savings of electricity can be achieved by improving the motors performance.
Actual load of the machine is not known and electrician’s select oversized motor
to be on the safe side. Designers and suppliers of the machines want to ensure
that their units have ample power so they suggest a driver that is substantially
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Best Practices Report (Version 1.0) in Processing Sector
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Renewable Energy & Energy Efficiency Programme (REEE)
larger than the real requirement
When replacement of motor is required and if there is no exact rating motor
available in the industry, electricians install the next larger motor available in the
store. Later on, when correct sized motor is purchased, they do not replace it
and oversized motor continues to be in use.
A large motor is selected for some unexpected increase in the driven equipment
load which is not materialized. Process requirements are reduced but oversized
motors are not replaced.
Motors bearings and their alignment play an important part in their abnormal
operation. In more than 50% cases, the failure of motor is a mechanical cause
due to improper alignment and the failure of bearings.
Presently class I motors are not available in the Pakistan. These will have to be
imported and become very expensive when taxes are added in their prices.
Class II efficiency motors are manufactured by Siemens and ABB. Replacing
old efficiency class III motors by class II will save energy. However, it is not wise
to replace all the old motors but in stages like when one old motor is out of
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Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 25
Renewable Energy & Energy Efficiency Programme (REEE)
order, it could be replaced.
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Best Practices Report (Version 1.0) in Processing Sector
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January, 2008 26
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Comparison of Motor Efficiency
Also, management must ensure that the factors mentioned due to which over
sized motors are installed, should be avoided.
Replacement of under loaded motors with smaller motors will allow a fully
loaded smaller motor to operate at higher efficiency. This arrangement is
generally most economical for larger motors, and only when they are operating
at less than one third to one-half capacity. Larger motors are typically installed
at the filters and air conditioning units.
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Renewable Energy & Energy Efficiency Programme (REEE)
Motor cooling fans should also be of proper size because these also consume
energy. Though these are fitted with the motors by the manufacturer, still their
working can be monitored and can be improved and adjusted if required.
Appropriate ventilation
Cleaning of motor body
Monitoring of motors with regard to noise, vibration and heating
Frequent alignment checking
It is recommended that the mechanical and electrical staff should have the
checklist for regularly monitoring the maintenance and upkeep of motors.
Where inverters are placed, high peak voltages can be experienced at the
motor terminals especially when the distance between the inverter (drive) and
the motor exceeds about 15 meters. Some additional heating to the motor
windings will inevitably occur because of the inverter's "synthesized" AC wave
form.
In case, motors are very old then the first choice should be to replace them, one
by one, if it is feasible. It is not advisable to invest on older motors and place
inverters. The best use of inverter is for variable flow applications. In case of air
conditioning plants, the flow is changed by changing the angles of the fans.
When the flow is reduced, motor takes less amperes but it operates at less
efficiencies. The better way to control the flow is through changing the speed of
motor by using frequency inverters.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 28
Renewable Energy & Energy Efficiency Programme (REEE)
17 COMPRESSED AIR SYSTEM
17.1 PROBLEM
Most of the industries are using piston type compressors but screw type is more
efficient.
The energy and cost savings are dependent on the size of the compressor, the
load factor, and the number of hours during which the compressor is used. The
load factor is the average fraction of the rated load at which the compressor
operates. The load factor is fairly constant for compressors that operate only
when they are actually compressing air. Most reciprocating compressors are
operated in this manner. When on, they operate with fairly constant power
consumption, usually nearly equal to their rated power consumption; when they
are cycled off, the power consumption is zero. Screw compressors are often
operated in a different manner. When loaded (i.e. actually compressing air),
they operate near their rated power, but when compressed air requirements are
met, they are not cycled off but continue to rotate and are unloaded. Older
screw compressors may consume as much as 85% of their rated power during
this unload state. Therefore, if a screw compressor is to be operated
continuously, it should be matched closely to the compressed air load that it
supplies. Often, plant personnel purchase compressors having several times the
required power rating. This may be done for variety of reasons, but often in
anticipation of expansion of the facility and a commensurate increase in the
compressed air requirements.
Pressure Gauges
Mostly pressure gauges are not installed on the machines or even if installed
then they might not be calibrated.
Auto Drains
Mostly, no auto drain is installed in any of the receiver tanks of the compressors
to control compressed air quality. Due to this, air moisture is not removed
effectively.
Air Leakages
Air leaks around valves and fittings in compressor air lines may represent a
significant energy cost for the mill. Sometimes up to 20% of the work done by
the compressor is to make up for air leaks. The energy loss as a function of the
hole diameter at an operating pressure of 6-7 bar is shown in Table
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 29
Renewable Energy & Energy Efficiency Programme (REEE)
Energy Loss from air Leaks
Hole Diameter Free Air Wasted (m3/year)By Energy Wasted per Leak
(mm) a Leak of Air at 7 bar (kWh/h)
9.5 2,500,000 30
6.5 1,100,000 14
3.0 300,000 3.5
1.6 70,000 0.9
0.8 15,000 0.2
Mostly, for cleaning compressed air is used through large 8.5 mm diameter pipe,
resulting into energy losses.
Air Leakages
Maintenance crew should survey the air distribution system and identify all the
leaking points. These points should immediately be rectified to avoid energy
losses. This measure does not require investment.
Cleaning Points
For reducing air consumption, it is recommended that the pipes of 8.5 mm
diameter or more, used for the air cleaning, should be replaced with the 6 mm
diameter with air guns. It will allow reduction in air use and ultimately the energy
consumption. Investment for this measure is nominal.
Air Quality
Use of moist air in the machines and the compressor affects their performance.
Manual bleeding off the receiver tanks is not a good practice as it wastes too
much compressed air. It is recommended to install auto bleeders on these tanks
to avoid this loss. For the better quality air, management should also use dryers
and line filters.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 30
Renewable Energy & Energy Efficiency Programme (REEE)
performance.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 31
Renewable Energy & Energy Efficiency Programme (REEE)
18 LIGHTING
18.1 PROBLEM
Magnetic Ballasts
In most of the units 40/36 watts tube lights are used. These tube lights consume
more energy as compared with the 36/28 watts tube lights with the same
lumens. These tube lights are attached with the conventional magnetic ballasts
which are not considered energy efficient. These ballasts waste energy in heat
and noise.
It will be helpful in improving lighting intensity if more lights are placed over the
machines not on that places like aisle and idle places. Lighting can also be
improved by reducing the height of the tube lights fixtures.
Electronic Ballasts
It is recommended to replace 40 watts tube lights with the 36 watts lights to
reduce electricity consumption. Tube light of 36 watts is available in two types
with different lumens. Detail of 40 and 36 watts tube lights is given in Table.
Typeof Tube Light Lumens Lamp life (Hours) Unit Price (Rs)
TL 40 Watt 2,500 6,000 55-60
TLD 36/54 Watt 2,650 13,000 50-60
TLD 36/80 Watt 3,350 15,000 90-100
40 watt tube light with ballast consumes about 52 watts whereas 36 watts tube
light with ballast consumes 44 watts i.e. 10 watts less. About Rs. 150 can be
saved per year per tube light by replacing 40 watts tube light with 36 watts.
Turn off the lights during break hours or when no body is present at work
place
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 32
Renewable Energy & Energy Efficiency Programme (REEE)
Use the natural light at day times wherever possible and as much as possible
Most of the electronic ballasts available in the market are of 380 volts which can
not operate at the current voltage of 415 volts in the industry. While purchasing,
ballasts, one must consider this aspect and purchase only those ballasts which
can withstand 415 volts.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 33
Renewable Energy & Energy Efficiency Programme (REEE)
19 REUSE OF CLEAN HOT WATER STREAM OF JETS
19.1 PROBLEM
In the industries where jets are used for scouring, washing and dyeing, two
types of hot wastewater streams are generated, contaminated and non-
contaminated, at a temperature of 50-80oC from the jets.
Contaminated streams are generated when chemical or dye solutions are
directly discharged or fabric washing is carried out. The clean wastewater
streams are those which are generated as a result of indirect cooling. Indirect
cooling means that the fresh water is passed through the jet heater, instead of
steam, and cools down the hot chemical or dye solution of the jet at a
temperature of 80 to 100 oC. Both these solutions remain in circulation in the
heater and transfer heat without any contact with each other. The fresh water,
after acquiring heat of the hot chemical or dye solution, becomes hot and
continuously wasted. This is a clean hot water stream at a temperature of 60 to
70oC which can be collected and reused in the jets or in the pre-treatment.
Title
Best Practices Report (Version 1.0) in Processing Sector
Date
January, 2008 34
Renewable Energy & Energy Efficiency Programme (REEE)