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ENERGY CONSERVATION OPPORTUNITIES IN TEXTILE MILLS

ENERGY CONSERVATION OPPORTUNITIES IN TEXTILE MILLS . STRIKING CASE STUDIES A PRESENTATION BY TENSOR CONSULTING ENGINEERS (CHENNAI) PVT.LTD 08.08.09 at TIRUPUR. CASE STUDY 1 Present System A modern spinning mill located at Madurai of 1Lakh spindles

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ENERGY CONSERVATION OPPORTUNITIES IN TEXTILE MILLS

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  1. ENERGY CONSERVATION OPPORTUNITIES IN TEXTILE MILLS STRIKING CASE STUDIES A PRESENTATION BY TENSOR CONSULTING ENGINEERS (CHENNAI) PVT.LTD 08.08.09 at TIRUPUR

  2. CASE STUDY 1 • Present System • A modern spinning mill located at Madurai • of 1Lakh spindles • AWES supplied by various manufacturers • Centrifugal blowers are used in the AWES • supplied by VXL for 18 cards • Observation • It was observed that the fans are energy in efficient • The operating load of the fans were 45Kw and 47Kw respectively • Cleaning interval of the secondary filter is very frequent • Proposal Implemented • The existing fans were replaced with high efficiency specially designed centrifugal blowers • The energy consumption reduced by 30% ie 32Kw each • The investment for implementing this proposal Rs.8Lakhs • The payback period is 10 months TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  3. CASE STUDY 2 • Present System • Reputed corporate group of mills located in Tamilnadu • Continuous AWES supplied by various manufacturers • There were totally 36fans in various AWES • Observation • It was observed the existing fans are energy in efficient • Cleaning interval of the secondary filter is very frequent • Proposal Implemented • The energy savings achieved by replacing these centrifugal blowers is between 20% to 40% • The average payback period is just less than an year TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  4. CASE STUDY 3 • Present System • Reputed corporate group o f mills located in Kerala • AWES supplied by various manufacturers • centrifugal blowers are used in the AWES in a system supplied by cross roll • Observation • AWES was supplied by cross roll • Primary disc filter and secondary drum filter in sheet metal enclosure is provided • The operating load of main centrifugal fan is 37.7Kw • Proposal Implemented • The existing AWES supplied by cross roll was replaced with energy efficient system • The operating load after replacement is only 15.7Kw • A substantial 58% reduction in energy consumption • Savings achieved • Annual savings Rs.8.5Lakhs • Investment is Rs.16Lakhs • Pay back period 2years TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  5. CASE STUDY 4 • Present System • A corporate group of mills located in Tamilnadu • Comber noil collection system supplied by BatliBoi • The system had condenses and centrifugal fans • Observation • The operating load of the system was 44.5Kw for 12 combers • Proposal Implemented • The system was replaced with FSC and aerofoil blade centrifugal fans • The operating load reduced to 14.5Kw • Savings achieved • Annual savings Rs.11Lakhs • Investment is Rs.7Lakhs • Pay back period 8 months TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  6. CASE STUDY 5 • Present System • A corporate group of mills in Tamilnadu without AWES • for blow room • Transport blowers are used along with aero filter and • BatliBoi system for microdust collection in blowroom • Observation • The operating load of the system was 63Kw • Proposal Implemented • AWES in sheet metal enclosure with multidrum filter • installed • The operating load after modification is 20 Kw • Savings achieved • Annual savings Rs.15Lakhs • Investment is Rs.15 Lakhs • Pay back period 12 months TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  7. CASE STUDY 6 • Present System • Carding AWES supplied by BatliBoi for 16 cards • Operating load is 73Kw • Carding AWES supplied by VXL for 4 cards • Operating load of VXL AWES is 30Kw • Total operating load for both systems is103Kw for 20cards • Proposal Implemented • Provided one AWES in sheet metal enclosure with multidrum filter for 10 cards • Replaced the existing fans with high efficiency fans in BatliBoi AWES and connected to 10 cards • Savings achieved • The operating load after this modification reduced to 60Kw • A whopping 40% reduction in energy consumption • The annual savings Rs.15.5Lakhs • The investment is Rs.22Lakhs • The pay back period is 17Months TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  8. CASE STUDY 7 • Present System • A leading corporate group of mills having spinning, Weaving & processing units • There are totally 82 humidification plants • All plants provided with conventional spray systems • Observation • The pump rating in conventional spray system is 5hp to 15hp • Pumps are operated for nearly 6000hrs per year • Proposal Implemented • The existing spray system was a replaced with high pressure spray system [‘Fog Master’] • Water sprayed at a pressure of 70bar • The pump installed capacity and operating load reduced by 80% • For example a 15hp pump replaced with 3hp pump • The complete reengineering package was executed and 30% energy savings achieved in all the 82plants • The average pay back period is one and half years TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  9. CASE STUDY 8 • Present System • A corporate mill located in Kerala • OE Department • 80,000cfm humidification plant supplied by BatliBoi • Plant capacity was inadequate • One more plant of 80,000cfm was to be added • Observation • The airflow delivered by the present fan is around 76,000cfm with an operating load of 24Kw • Proposal Implemented • One more plant of 80,000cfm was added with very highly energy efficient design features • The plant outlet was connected to the existing supply air plenum • The new energy efficient design was able to deliver 80,000cfm with just 8Kw of power • The incremental cost was paid back in two and half years TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  10. CASE STUDY 9 • Present System • A reputed corporate mill having presence in diversified industries • Unit is located at Madurai • Order was placed for 10,000 spindles spinning project with Batli Boi • Proposal Implemented • High efficiency axial fans were supplied instead of Batli Boi fans • The spray system was modified from conventional to high pressure system. • Ducting was redesigned using static regain techniques • Savings achieved • 40% reduction in the power consumption • The pay back period was one and half years TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  11. CASE STUDY 10 • Present System • A leading corporate mill • 32,000 spindles new project • Complete rieter machine with auto doffing and Murata link coner • Proposal Implemented • Complete project executed with • Multi drum filters in humidification plants with automatic control • High pressure system in humidification plants • High efficiency axial flow fans • Energy efficient humidification plant design • Ducting design with linear diffuser using static regain method • The energy consumption of humidification plants & AWES compared with their own other units is less by 40% • The incremental cost was paid back in two years • Savings achieved • 40% reduction in the power consumption • The pay back period was one and half years for the incremental cost TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  12. SUM - UP • Excellent savings potential in AWES and Humidification Plants. • Very attractive payback period of less than one year. • Proven in many reputed mills. • Simple retrofitting from fan replacement to system replacement. • New projects offers potentials as high as 40% savings in energy. TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

  13. THANKING YOU TENSOR CONSULTING ENGINEERS (CHENNAI) PVT LTD

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