Assignment # 3

Topic: Fuel Economy in Textile Industry.

NAME: Mohammad Muddaser Sharif

Roll No# 07-NTU-087

Department: Fabric Manufacturing

Semester: 6th

Date of Submission: 04-02-2011

Submitted to: SIR HASSAN SB

National Textile University

 FUEL ECONOMY IN TEXTILE MILLS

Heat generated through the combustion of fuel is utilized to generate steam from
water in a boiler and to heat thermal fluid in a thermal fluid heater. Heat of the steam and
the thermal fluid is utilized in various textile processors. Ever escalating fuel cost has
increased the cost of heat energy to a considerable extent, which is one of the important
factors contributing to the higher processing cost, and hence the production cost of textile.
Higher production cost thin profit margins; tough global competition collectively has posed a
serious problem for survival of Textile Industry.

Therefore, every possible step has to be taken to lower the production cost. Heat
economy i.e. conservation of thermal energy is a major option in this regard. Heat economy
is nothing but efficient generation and utilisation of heat energy. Scope for heat economy i.e.
conservation of thermal energy exists during generation and utilization of thermal energy,
recovery of waste heat, etc. Some general suggestions for heat economy have been given
in the following:

STEAM GENERATION

 Monitor the Combustion Efficiency and other related combustion parameters like
O2, stack
 temp. etc. of the boilers on regular basis and take corrective actions immediately
to attain the optimum efficiency.
 Load the boilers to 80-85% of their rated capacity, for optimum performance.
 Avoid frequent start-stop of the boilers.
 Avoid banking losses of a boiler; operate only the requisite numbers of boilers as
per the demand for steam.
 Limit the boiler steam pressure to the requirement of the machines, giving due
allowance for the pressure drop in the steam distribution system.
 Adjust boiler blowdown keeping in view the TDS levels prescribed for different
types of boilers.
UTILISATION OF STEAM

 Provide/set right pressure reducing valves in the steam supply lines of

machines in order to obtain steam at the required lower pressure.
 Provide non-return valves after the traps to avoid back pressure from the
closed condensate system.
 Provide traps of proper type and size and install them properly to ensure
complete condensate removal.
 Plug leakages of steam from cylinder head joints, flanged joints, valve
spindles, etc,.
 Provide adequate lagging for the hot bare surfaces in steam lines, cylinder
ends and machine surface, etc.
 Provide temperature control valves for jiggers, soapers, etc. to avoid wasteful
consumption of steam.
 Check the working of control valves installed at stenters, printing machine
dryers, etc. for optimum use of thermal energy.
 Plug the air leakages from the chamber doors of hot air stenters etc. to avoid
wastage of hermal energy.
 Improve squeezing of fabrics through the mangles to reduce the thermal
energy consumption for dryers, stenters, etc.
  Modify processing sequences so as to eliminate some of the hot wash/drying
operations.

HEATING OF THERMIC FLUID

 Follow the points given for improvement of the efficiency of boilers.
 Restrict the heating of thermic fluid to the requirement of process/machine.

RECOVERY OF WASTSE HEAT

 Collect condensate from all indirectly heated machines.

 Instal flash steam recovery system to generate low pressure steam from the high
 pressure, steam condensate.
 Instal heat recovery system for recovering the thermal energy from effluent of jet
dyeing and other dyeing machines, etc.
 Instal waste heat boiler/Heat Recovery Unit (HRU) for the generation of hot
water/steam
 by extracting heat from the hot flue gasses of thermic fluid heaters and D.G. sets.
 Modify the Caustic Recovery Plant by providing additional effect.
CASE STUDY – 1

General Background

This is a process house unit situated in Navy Mumbai. It is engaged in processing of

knitted and woven fabric. The unit’s processing capacity is 50,000 m/day.
Fuel used in boiler & thermal fluid heater: Furnace Oil The average fuel oil consumption:
14 .50 KL

Thermal Energy Audit Recommendations Implemented by the Unit

 Tuning of the boiler for reducing excess air and thorough cleaning of its heat transfer
 surfaces: thermal efficiency improvement from 82.5 to 84.0%
 Incorporating automatic blowdown control system at boiler; 40% blowdown quantum
reduced.
 Repair of pressure reducing valves installed in three main steam supply lines.
 Attending malfunctioning steam traps (15 Nos.)
 Closing trap by-pass line valves ( 23 Nos.)
 Providing individual trapping system instead of group trapping for drying range
machines.
  Recovery of condensate from 9 dyeing machines, 2 drying range and 1 zero-zero
machine and using it as boiler feed water.
 Plugging steam leakages (53 Nos.).
 Lagging of cylinder ends of both the drying range machine. Lagging of hot bare
surfaces in thermic fluid heating system.
 Overhauling of TPA-10 Thermic fluid heater; its thermal efficiency improved from 73
to 79%.
 Fuel Saving : 350 KL (Rs.39 lakhs)/Annum.
 Fuel Saving as % of consumption : 7.8%

CASE STUDY – 2

General Background

This is a process house unit situation in Surat, Gujarat. It is engaged in processing

P/V shirting. The unit’s processing capacity is 60,000 metres per day. Fuel used in boiler &
thermal fluid heater : Coal The average fuel consumption : 8.0 MT

Thermal Energy Audit Recommendations Implemented by the Unit

 Proper tuning of the thermic fluid heater for reducing excess air; thermal efficiency
improved from 55% to 65%.
 Lagging of hot bare valves in thermic fluid heating system (66 Nos.)
 Plugging steam leakages (6 Nos.).
 Fuel Saving : 400 MT(Rs.11.6 lakh)/Annum.
 Fuel saving as % of consumption : 16.50%

CASE STUDY – 3

General Background

This is a process house unit situated at Pali, Marwar, Rajasthan. It is engaged in

processing of spun x spun sari. It’s processing capacity is 40,000 metres per day. Fuel used
in boiler & thermic fluid heater : Lignite The average fuel consumption : 18.5 M.T.
Thermal Energy Audit Recommendations Implemented by the Unit

 Adjusting of air dampers in the thermic fluid heater; its thermal efficiency improved
on the spot from 52% to 58%.
 Lagging of hot bare valves in thermic fluid heating system (89 Nos.)
 Plugging steam leakages (4 Nos.).
 Shutting trap by- pass valves (3 Nos.)
 Attending malfunctioning traps(3 Nos.).
 Attending punctured main condensate line
 Fuel Saving : 470 MT (Rs.6.8 lakh)/ Annum.
 Fuel saving as % of consumption : 8.50%