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DESIGNING AN ELECTRICAL ENERGY CONSERVATION PROGRAM IN A WET PROCESSING FOR A LOCAL TEXTILE
INDUSTRY
DESIGNING AN ELECTRICAL ENERGY CONSERVATION PROGRAM IN A WET PROCESSING FOR A LOCAL TEXTILE
INDUSTRY
ALEEM BUTTALEEM BUTT
INTRODUCTION
• Energy conservation commonly abbreviated as ENCON according to (Oxford Dictionary of Abbreviation, 1998) is the act of using energy in a more efficient and effective manner.
SIMPLE CONCEPT OF ENERGY EFFICIENCY AND CONSERVATION
WHAT DOES ENERGY CONSERVATION DO
• Reducing the emission of greenhouse gases which contribute to global warming
• Also saves costs for individuals and businesses, giving them higher productivity and enhanced profitability due to cost savings from energy bills.
• promote economic security and sustainability.
WHY ENERGY CONSERVATION IS IMPORTANT FOR DEVELOPING COUNTRIES
• Energy conservation (ECON) becomes critically important for the third world countries like Pakistan, where the energy crises, rising energy costs and therefore efficient energy equipments are of significant concern to both the industry and the utilities.
• Pakistan ranks 30th in terms of world energy consumption in year 2006 (BP, 2006).
STUDY DYNAMICS
• Industrial Sector – Major Power Consumption• Textile – Major industrial Sector• Wet Processing - Desizing, Scouring, Bleaching, Mercerizing, Singeing, Raising, Calendaring,
Shrinking, Dyeing, Finishing and Printing
• Motors• Compressors • Lighting Systems • Air Conditioning Systems • Ventilation System • Computers Printers
Equipment's Under Study
INDUSTRIES UNDER STUDY
• As study sample, we have taken 2 industries
1)MK Sons Textile 2 KM Khurruanwala, Faisalabad
2) Kohinoor Textile Mills Manga Raiwind Road Lahore
AIMS & OBJECTIVES
• Implement potential general and technical conservation strategies after evaluating energy usage patterns
• Reduction of actual consumption of energy without process design modification.
• Preparation of management plans and strategies to maximize the system efficiency and effectiveness of energy inputs.
• Environmental protection by reduction in green house gas emissions through energy conservation and reduce industrial carbon emissions by increasing energy efficiency.
AIMS & OBJECTIVES
• Gaining monitory direct benefit in terms of minimizing the energy bills expenditure, maximizing the productivity and profitability.
• Causing the indirect benefits for the country in terms of energy conservation in current energy crises situation to promote economic security.
• Promoting best management practices that can trigger chain of relevant energy conservation along with boosting the productivity, efficiency and effectiveness.
METHODOLOGY
INSTRUMENTATION
• Lux Meter• Electric Power Demand Analyzer • Power Factor Meter• Voltmeter• Ammeter • Air Flow Meters • Voltmeter • Tachometer
RESULTS & DISCUSSION
• Electrical Utility Cost in MK Sons Textile MillMK SONS TEXTILE MILL (WET PROCESSING)
Sr. No.
Name of Equipment
Machinery Type
Quantity
(Nos.)
Total Load
(KW)
Cost of Electricity
(Rs./day)
Cost of Electricity (Rs./Year)
based on 353 days
1 Motors Bleaching
Plant 102 250 44750/-
15,79,675
0/-
2 Motors Merchandi-
zing 79 97 17363
6,12,9139/-
3 Motors Pud Steam
Cum Washing
80 140 25060 8,84,6180/
-
4 Motors Senging / Desizing
14 44 7876 2,780,228
5 Motors Dyeing
Jiggering 06 66 11814 4,170,342
6 Motors
General Exhaust
Ventilation/ Fans
02 2.2 394 13,9082/-
7 Compressors Compressor 04 4 716 2,52748/-
8 Fluorescent
Lamps Fluorescent
Lamps 400 18 3222
11,37,366/
-
9 Computers
and Monitors
Computers, Monitors
inside small offices in
production hall (based on 12 hours operation)
12 3.9 698 2,46,394/-
10
Printers (during Printing Mode)
Printers inside small
office in production hall (based
04 1
9.0
(Average of peak and
off peak
3,177/-
RESULTS FORM THE IMPROVEMENT AND CONSERVATION ANALYSIS
• Opportunities Dynamics • Day Light Harvesting• Good House Keeping• Improving ILER- Msurement • Improving Compressors- Environment• Replacing Motors • Improving Ventilation Systems • % Energy Efficiency Improvements
DAY LIGHT HARVESTING
Measures Taken in MK Sons Textile
•Changing on Roof Glass & Sliding Windows
•Windows frame painted light in Color and anti glare finish
•The measures reduces the lighting load upto 50 % that saves 3300 KW/Per Year almost Rs. 25000/- per Year
DAY LIGHT HARVESTING
Measures Taken in Kohinoor Textile
•Windows glass replacement of slider windows •Photo sensors has been installed with the lighting systems
•15 % Saving from windows glass replacement and 5 % from photo sensors. Total 20 % saving Energy save 9000 KW with amount 70,000 per year having pay back of photo sensors 4 years
PROVISION OF TOP LIGHTING IN MK SONS TEXTILE
GOOD HOUSE KEEPING MEASURES
• Following Behavioral practices were adopted in both textile which saves almost 70 % of energy in lightening, computer appliances and air conditioners.• Proper cleaning and staff motivation to turn off lights
of unoccupied areas saves almost 1 % of energy • Switching off the appliances when not in use and
proper plug out during night time saves almost 8 % of energy • 60 % of energy is saved from AC by proper insulation
of rooms, cleaning air filters and regulating AC at 26 C
GOOD HOUSE KEEPING
• The wastages and leakage from lighting were Rs. 12000 to 15000 (1600-2000 KW), computers appliences Rs. 18000 to 20,000 (2400-2600 KW) and air conditioning systems 115,000 to 120,000 (15000-16000 KW) per year is saved by changing and managing human behavior.
ILRE MEASUREMENT
• The overall lighting performance was calculated by finding ILER (Installed Load Efficacy Ratio) with reference to the energy wastages
Sr. No
Description Unit Reading
1 Date 26/04/2012
2 Time of Measurement 1:00 PM to 6:00 PM
3 Room Identification Wet Processing Hall
4 Type of Activity Wet Processing
5 Number of Lamps 5
6 Length of the part of hall M 11
7 Width of the part of hall M 8
8 Area of Part of hall m2 88
9 Height of the lamp M 3.1
10 Room Index (in accordance with room index formula)
1.50
11 Number of points taken for Lux 16
12 Average part of Hall luminance, F Lux 150
13 Measured and Estimated circuit Power, P
W 250
14 Watts Per Meter Square W/m2 2.84
15 Lux Per Watt Per Meter Square Lux/W/m2 52.81
16 Target Lux Lux/W/m2 58
17 Installed Load Efficacy (ILER) Lm/W 0.91
ILRE MEASUREMENT
• The cost of annual energy wastage in terms of lighting in wet processing hall of MK Sons Textile Mills was about 190 KW per year which cost about Rs.1463 per year with the production capacity 2.8 million mili meter per month as compared to Kohinoor Textile Mills where it was 762 KW per year which cost about Rs. 5715 per year with the production capacity 1.8 million mili meter per month.
IMPROVEMENTS IN ILER BY MEASURES
• Reflectors cleaned and painted that improves the luminary efficacy.• Lamps height was reduced from 2.7 to 2.0 meters that improved the room
index from 1.71 to 2.31• Walls white washed and proper cleaning of floor • The above measures improved the average Lux value from 140 to 230 and
reduced the annual energy wastage from 762 KWH to 150 KWH and it saved the cost of almost Rs. 5000/- per year in kohinoor textile
• In the same pattern improvements measures had also been taken in MK Sons Textile Mills which further reduced the energy consumption by 190 KWH per year and saved Rs. 1463 per year.
COMPRESSORS
• Wastages from Free Air Delivery Test (FAD)
• Inefficiency in compressors
• MK Sons Textile – 0.659 KW/h -Rs. 41640 per year.
• Kohinoor Textile Mills - 1.86 KW/h - Rs. 120810 per year.
MEASURES IN COMPRESSORS
• Small Sheltered room
• Cool Dry Air and ducting between air intake and compressors
• After implementing Measures
The energy savings in MK sons textile were 0.319 KW/h and in Kohinoor textile 1.34 KW/h. With the subsequent cost saving of Rs. 21459/ year at MK Sons Textile Mills and Rs. 84575/ year at Kohinoor Textile Mills respectively.
LEAKAGE TESTING OF COMPRESSORS
Parameter Unit MK Sons Textile Mills Kohinoor Textile Mills
Q m3/min 0.5 2.49
T Min 1.5 2.0
T Min 7.5 11.5
System Leakage m3/min 0.083 0.368
Leakage Quantity Per Day m3/day 119 531.2
Specific Power For Compressed Air Generation(Measured Power During Loading ÷
(Compressor Capacity × 60)
KWh/m3 0.04 0.053
Energy Lost due to Leakage Per Day
(Specific Power for compressed air × Leakage quantity per day)
KW/day 4.76 28.1
LEAKAGE TESTING COMPRESSORS
• 3.6 % air leaks were detected in MK Sons Textile Mills
• 11.3 % air Leaks were detected in Kohinoor Textile Mills
ENERGY SAVE AFTER IMPROVEMENTS OF LEAKS IN COMPRESSORS
• All the leaks in relief valves, joints, quick release couplings, shut off valves etc were repaired. After improvement of air leaks The total energy saved in MK sons Textile Mills was 4.756 KW/day and in Kohinoor textile it was 28.0 KW/day and the cost of energy saved has been Rs. 12491/ year and Rs. 73635/ year respectively.
MOTORS
• Rewound motors in both industries were replaced with energy efficient motors and they have given immediate benefits. 40 Nos. rewound motors in MK Sons Textile Mills were replaced with energy efficient motors. The total investment was almost Rs. 250,000/- which would save Rs. 80,000 per year with capital investment pay back is just 3 years. Similarly in Kohinoor textile 25 Nos. rewound motors were replaced with energy efficient motors having investment Rs. 150,000 which would save Rs. 50,000 per year and the pay back of capital investment is 3 years.
VENTILATION SYSTEM
VENTILATION RESULTS
Sr.
No.
Industry Indoor CO2
Level
(ppm)
Outdoor
CO2 Level
(ppm)
Difference
of Indoor
and
Outdoor
Levels
(ppm)
CFM per
Person
(10500÷
Difference of
indoor and
outdoor levels)
1 MK Sons Textile
Mill
680 345 335 31.3
Kohinoor Textile
Mill
540 360 ppm 180 58.3
ENERGY IMPROVEMENTS IN VENTILATION SYSTEMS
• Variable speed drivers had been installed on the motors of General Exhaust Ventilation Systems which enabled the adjustments of CFM per person set at 25 CFM in both industries.
• These measures have resulted in energy saving of 0.5 KW/hr i.e. equivalent to Rs. 31,727/ year and 0.7 KW/hr i.e. equivalent to Rs. 44,418/ year in M/S MK Sons and M/S Kohinoor Textile Mills respectively.
COST BENEFIT ANALYSIS No. of Obs. Energy Saving Measures
InvestmentRs.
SavingsRs./Year
Pay Back Period (Years)
1Changing of dark colored mirror of windows and roof aperture to ultra clear and clear mirror in MK Sons Textile Mill. Properly positioned mirror and painted
light color to the windows frames40,000/- 25000/- 2
2Provision of the slide windows (Harvesting Day Lighting) and installation of
photo sensors in Kohinoor Textile Mill250,000 70,000/- 4
3Energy Conservation by cleaning windows & floors and encouraging staff to
turn off lights of unoccupied areasNil 10,000-15,000/- -
4Turning off the appliances like Computers, monitors, photocopiers, and printers etc when not in use and properly plugged out over night. Also Battery chargers
were unplugged when batteries were fully charged or charger was not in useNil 19000/- -
5 Regulating Air Conditioner thermostat 26 ºC instead of 20 ºC Nil 114372/- -
6Properly cleaning of reflectance and lowering of lamp height form 2.7 meters to
2.0 meters in Kohinoor Textile Mill.10,000/- 5000/- 2 Years
7Replacing of Conventional Fluorescent Lamp with LED lighting system in
Kohinoor Textile Mill if replaced all in the hall1407000/- 507791/- 2.7 Years
8Replacing of Conventional Fluorescent Lamp with LED lighting system in MK
Sons Textile Mill if replaced all in the hall140,0000/- 619515/- 2.2 Years
No. of Obs. Energy Saving MeasuresInvestment
Rs.SavingsRs./Year
Pay Back Period (Years)
9Improving FAD of the compressor by building small sheltered room for intake of cool and dry air in MK Sons Textile Mill
40,000/- 21459/- 1.9 Years
10Improving FAD of the compressor by building small sheltered room for intake of cool and dry air in Kohinoor Textile Mill
60,000/- 84575/- 0.7 years
11Repairing of the air leaks in joints, valves, couplings etc and
maintenance of the compressor in MK Sons Textile Mill- 12491/- -
12Repairing of the air leaks in joints, valves, couplings etc and
maintenance of the compressor in Kohinoor Textile Mill- 73635/- -
13Replacing Rewound motors with energy efficient motors in MK
Sons Textile Mill250,000/- 80,000/- 3.1 Year
14Replacing Rewound motors with energy efficient motors in
Kohinoor Textile Mill150,000/- 50,000/- 3 Years
COMPARISON OF EFFICIENCY OF ENERGY EFFICIENCY IMPROVEMENTS MK SONS TEXTILE MILL V/S KOHINOOR TEXTILE
MILLS
Sr.Conservation
Measure
Cost of Energy (Before)
MK Sons Textile
Cost of Energy (After)
MK SonsTextile
Energy Efficiency Improve-ments
(%)MK Sons
Textile
Cost of Energy (Before)
KohinoorTextile
Cost of Energy (After)
Kohinoor Textile
Energy Efficiency Improve-ments
(%)Kohinoor Textile
1Day Light Harvesting
155078/- 77539 50 429123 343299 20
2
Energy Conservation by cleaning windows & floors and encouraging staff to turn off lights of unoccupied areas.
9988 9789 98 12445 12072 97
3
Turning off the appliances like Computers, monitors, photocopiers, and printers etc when not in use and properly plugged out over night. Also Battery chargers were unplugged when batteries were fully charged or charger was not in use
18667/- 17734 95 20677/- 2067 90
COMPARISON OF EFFICIENCY OF ENERGY EFFICIENCY IMPROVEMENTS MK SONS TEXTILE MILL V/S KOHINOOR
TEXTILE MILLS
Sr.Conservation
Measure
Cost of Energy (Before)
MK Sons Textile
Cost of Energy (After)
MK SonsTextile
Energy Efficiency Improve-ments
(%)MK Sons
Textile
Cost of Energy (Before)
KohinoorTextile
Cost of Energy (After)
Kohinoor Textile
Energy Efficiency Improve-ments
(%)Kohinoor Textile
4 Regulating Air Conditioner thermostat 26 ºC instead of 20 ºC
114,372 0 100 194,239 0 100
5 Improving ILER by lowering lamp height
1501 756 50 6020 1020 83
6 Efficiency improvement in FAD of the compressors
41640 20181 48.4 120810 36235 29.9
7 Air Leakages in Compressors
12518 12491 88 73898 73635 84
8 Replacement of Rewound Motors
6311640 6231640 1.3 3786984 3750984 1.0
CONCLUSION
• The total energy efficiency achieved from all the measures has been 61.4 % and 58 % in MK Sons Textile and Kohinoor Textile respectively.
• Both firms do have the tendencies for further energy efficiency progress up-to 25-30% but that do require monetary investments in-terms of sophisticated technical and human resource development.
• About Rs. 10 – 20 Million/ year savings in industry in terms of money is achieved through these simple efficiency measures
CONCLUSION
• This study concluded that there many opportunities of energy savings, which are existent in this sector but due to lack of effective governance and energy conservation policies, deficient worker’s awareness, training and motivation plans, huge amount of energy is wasted that is reflected in terms of huge financial and economic loses to the industry and to the country.
THANK YOU