Energy Conservation Potential of Measurement & Control Systems and Energy-Saving Equipment In Textile (Dyeing) Processes by: Dr. Attia Saad El-Din Energy

Energy Conservation Potential of Measurement & Energy Conservation Potential of Measurement & Control Systems and Energy-Saving EquipmentControl Systems and Energy-Saving Equipment

In Textile (Dyeing) ProcessesIn Textile (Dyeing) Processes

by:by:Dr. Attia Saad El-DinDr. Attia Saad El-Din

TIMS - Egypt

Energy Conservation Center, Japan & TIMSEnergy Conservation Center, Japan & TIMSMarch 2000March 2000

Baseline Cairo, March 31 & April 1, 2004

TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

IntroductionIn the textile industry, one of Egypt's major In the textile industry, one of Egypt's major industries, most of the equipment and machinery industries, most of the equipment and machinery appears to be outdated, and measuring equipment appears to be outdated, and measuring equipment is not sufficiently available. Hence, taking is not sufficiently available. Hence, taking appropriate measures will lead to a substantial appropriate measures will lead to a substantial saving in energy.saving in energy.In this context, a quantification of the energy In this context, a quantification of the energy conservation potential of Egypt's textile (dyeing) conservation potential of Egypt's textile (dyeing) industry, the effect on greenhouse gas reduction industry, the effect on greenhouse gas reduction and the effect of investment for these purposes is and the effect of investment for these purposes is expected to lead to the identification of great expected to lead to the identification of great opportunities that would contribute to achieving opportunities that would contribute to achieving CDM goals as well as to Egypt's national interest.CDM goals as well as to Egypt's national interest.



Schematic Diagramof Technologies Covered by the Project



Equipment Covered by the SurveyEquipment Covered by the Survey

Dyeing processDyeing processJet dyeing machines, winch dyeing machines, Jet dyeing machines, winch dyeing machines, mercerization dyeing machines, etc.mercerization dyeing machines, etc.

Drying processDrying processStenters, suction drum dryers, etc.Stenters, suction drum dryers, etc.

Utility facilities (heat sources for the dyeing and drying Utility facilities (heat sources for the dyeing and drying processes)processes)Steam boilers, thermal oil boilers, and the piping for Steam boilers, thermal oil boilers, and the piping for such boilers such boilers



Project Examined TechnologiesProject Examined TechnologiesThe following 5 items constitute the technical basis for energy conservation The following 5 items constitute the technical basis for energy conservation effect.effect.

1.1. Heat insulation of machine proper and steam piping Heat insulation of machine proper and steam piping2.2. Enhancement of measurement and control Enhancement of measurement and control 2.a Dyeing process: Attainment of optimum dyeing conditions2.a Dyeing process: Attainment of optimum dyeing conditions 2.b Drying process: Achievements of optimum drying 2.b Drying process: Achievements of optimum drying

conditionsconditions 2.c Finishing2.c Finishing3.3. Recovery of cooling water and heat recovery from hot/waste Recovery of cooling water and heat recovery from hot/waste

waterwater4.4. Recovery of condensate Recovery of condensate5.5. Introduction of energy management system Introduction of energy management system 5.a Optimization of boiler air/fuel ratio and operating pressure5.a Optimization of boiler air/fuel ratio and operating pressure 5.b Centralized energy management system of utilities5.b Centralized energy management system of utilities

(energy “fuel, steam, electricity”, water, … etc)(energy “fuel, steam, electricity”, water, … etc)



Current State of Subject Equipment by Factory



Base Line for Energy Consumption Type of Base Line for Energy Consumption Type of Equipment by Factory (Zenotex)Equipment by Factory (Zenotex)



Base Lines of Energy Consumption for 11 Factories Surveyed



Specific Energy Saving by Energy Specific Energy Saving by Energy Conservation MeasuresConservation Measures



Specific Energy Savings by Factory



Base Line for Emission Volume of Base Line for Emission Volume of Greenhouse Gases for Each FactoryGreenhouse Gases for Each Factory

t



Specific Reduction in Greenhouse Gas Specific Reduction in Greenhouse Gas Emission for Each FactoryEmission for Each Factory



Summary of COSummary of CO22 Reduction and Energy Conservation Reduction and Energy Conservation

Potential for 11 factory surveyedPotential for 11 factory surveyed

COCO22 Reduction ReductionEnergy SavingsEnergy Savings

ItemsItemsCalculation resultsCalculation resultsItemsItemsCalculation resultsCalculation results

COCO2 2 reduction volumereduction volume44,702 tons/year44,702 tons/yearEnergy reductionEnergy reductionVolumeVolume

14,449 toe/year14,449 toe/year

COCO22 reduction rate reduction rate22.422.4Energy reduction Energy reduction raterate

22.422.4

Investment costInvestment cost838.56 million yen838.56 million yenInvestment costInvestment cost838.56 million yen838.56 million yen

COCO22 reduction/ reduction/

million yenmillion yen53.3 tons53.3 tonsEnergy reduction/Energy reduction/

million yenmillion yen17.2 toe17.2 toe

Investment amountInvestment amountper ton of COper ton of CO22

18,750 yen18,750 yenInvestment cost perInvestment cost perunit of energy (toe)unit of energy (toe)

5,800 yen5,800 yen



Effect on ProductivityEffect on ProductivityThe promotion of energy conservation through measurement and The promotion of energy conservation through measurement and control recommended in this survey leads to the improvement of control recommended in this survey leads to the improvement of productivity.productivity.

Because optimum energy control in the manufacturing processes Because optimum energy control in the manufacturing processes allows automatic control of operation at the temperature, humidity, etc., allows automatic control of operation at the temperature, humidity, etc., most appropriate for production, the defective product rate declines most appropriate for production, the defective product rate declines significantly (yield improves) as compared with manual control. significantly (yield improves) as compared with manual control. Moreover, improvement of product quality can be expected.Moreover, improvement of product quality can be expected.

At present, Egypt's textile products are losing international price At present, Egypt's textile products are losing international price competitiveness with Southeast Asian products, and in this context, it is competitiveness with Southeast Asian products, and in this context, it is increasingly important to strengthen international competitiveness increasingly important to strengthen international competitiveness through higher quality and reduced prices, thereby promoting exports.through higher quality and reduced prices, thereby promoting exports.

While the improvement of quality, as well as that of productivity, is While the improvement of quality, as well as that of productivity, is necessary, this project is designed to attain these two purposes necessary, this project is designed to attain these two purposes concurrently, and it is thus considered to comply with the request of the concurrently, and it is thus considered to comply with the request of the Egyptian side.Egyptian side.



Effect on the Egyptian textile (Dyeing) IndustryEffect on the Egyptian textile (Dyeing) Industry

Reduction of approximately 22.4% (160,000 toe/y) of the Reduction of approximately 22.4% (160,000 toe/y) of the total energy consumption. total energy consumption.

Base line for this estimate:

1. Energy consumption by the textile sector: 1,433,000 toe/year

2. Energy consumption by the dyeing industry: 717,000 toe (50% of the total energy consumption).

3. Probable approaches to dissemination of the effect of this project include:

1. Financial assistance (Yen loans, "Carbon Fund" including WB and EPP Fund,

2. Technical assistance, 3. Development of human resources (training)



Documents

Energy Conservation Potential of Measurement & Control Systems and Energy-Saving Equipment In Textile (Dyeing) Processes by: Dr. Attia Saad El-Din Energy