d

Iv

+, 1 a

S -- Y a

r Y

.d

Y at 1

- Ring spinning frame Winder Comber Card Fly frame Blow room M/C Draw frame Compressor

Energy Saving Measures in Spinning,

59.4 14.9

8.1 6.4 4.8 3.0 1.4 1.4

I

Weaving and Dyeing Stages

r d e x % I I 1 0 ~ ~ \ i l ; : ; l I ll;:;8i l1;;W5 i22.1 3.09 No. of persons 20,s bale required

Japan Plant Engineering Co., Ltd.

122.8

2.62

1. Introduction The oil strategy put in motion by

OPEC and OAPEC in October, 1973, gave a great shock to the world econo- my. In fact, it put the world economy in a state of panic.

The sharp rise of oil price caused di- rectly the increase in costs of fuel, power, material, etc. and indirectly the shortage of commodities and deceler- ated economy. In particular, the sharp rise in manufacturing cost resulted in decreasing the earnings rate in the tex- tile industry to a large extent.

In Japan which depends 75% of energy sources upon imported oil and 57% of her gross output of electric power upon oil, each kind of industry has been wrestling earnestly with the problem of energy-saving and has pro- duced fairly good results. In the textile industry, the fact is that lecture meet- ings and symposiums on the measures ofenergy-saving at mills have been held in each group. Details of such measures are given below.

2. Energy-saving measures at spin- ning process

Energy-saving at spinning process is narrowed down to how to decrease the consumption of electric power.

The progress of electric power and working force required at spinning

Index % Unit price of Dnwer

mills in Japan is as shown below. It can be seen from Table 1 that as

compared with 1970, electric powedperson in the years after that in- creased largely. This increase may be attributed to the investment in labor- saving field and improvement of prod- uctivity by rationalization.

Any epock-making energy-saving machine has not been invented for the spinning process but noticeable results have been produced through accumu- lation of small ideas for energy-saving. Table 2 shows the distribution ratio of electric power required for each kind of production machine in the spinning process. Concrete energy-saving meas- ures taken for ring spinning frames and winders which are main machines in the spinning process and effect of such measures are shown in Table 3.

The distribution ratio is the rate of power consumption by each kind of production machine to total power con- sumption in the spinning section.

In the field of ring spinning process, a new device which realizes power-sav- ing of 1 KWH/set through conversion of the conventional tixed-type filter box of pneumatic clearer to the revolving cage type has been developed. This new device will be adopted on a full scale in the near future.

I I I

I 100 1 84.0 I 89.8 86.6 73.8 74.8 63.4 1 4.36 I 4.96 I 8.40 8.99 10.81 11.68 10.64 Yen,KW

I ~ - .. -- Power per

Index % -person KWH hrs.

JTN. Mav. 1981

Table 2

Distribution ratio (%) Process

In the tield of winder process, it is re- ported that the centralized blower sys- tem realized 34.8% power-saving, as compared with the conventional indi- vidual system. 3. Energy-saving measures at weav- ing process

In the field of weaving process, looms numbering from only several units to hundreds of units and preparing ma- chines, such as warpers, sizers and winders, in the number corresponding to the loon1 capacity and also machines for after-process, such as inspecting machines, are installed. Until recently, technological development has been carried out in pursuit of speedup, labor-saving and versatility, with good results. On the other hand, such devel- opment has brought about the increas- ing consumption of energy which, cou- pled with the rise in oil price, raised largely the share of energy cost in the total manufacturing costs.

In spite of the cry for energy-saving measures in the weaving process. large energy-saving in this process is not like- ly to be realized unless a fundamentally new principle and mechanism are em- ployed because the existing looms and other machines in the weaving process are the fruit of technological studies of a long history. Moreover, in the present trend of multi-item and small-lot pro- duction further improvements of looms

63

/ /

Table 3

I Process i Item -

Ring spinning frame

Auto winder

o Change of spindle wharve diameter o Change of elastic spindle tape o Adoption of bakelite pulley o Impeller cutting of pneumafil blower o Adoption of intermittent drive for

o Adoption of high efficient motor o Adoption of centralized blower system

overhead cleaner

Remarks: A : reduce

will be very difficult. Among machines used in the weaving

process, mention is made below about energy-saving for the sizer which con- sumes steam in a large quantity and the loom which is installed in a greater number , 1) Sizer

As the method of soaking ~ a r p in sizing liquid and then drying, Hot-air type, Multi-cylinder type and a com- bined type of the foregoing two are available. So far the Hot-air type was preferred even for sizing “spun yarn” but this type is poor in thermal efficien- cy, requires energy 40-50% more than the Cylinder type and is difficult to speed up. With the progress of teflon- coating technique in recent days, Hot- air type is being replaced by Multi-cyl- inder type.

Even in Multi-cylinder type, however, energy used for drying warp accounts tor 80% of the total and in order to de- crease the sizing liquid pick-up quanti- ty, a method of pressing the squeezing rollers at a high pressure has been de- veloped. If the pick-up quantity is re- duced from 130% to 100%, 20% energy- saving can be obtained but for this pur- pose, the optimum conditions must be l‘ound out for the pressure and hardness 01 squeezing roller, soaking range, pre- paration of size, etc. Besides, regarding thc foamy paste using an agent for the purpose of reducing the water content, it comes under consideration to use a sc1vet.t p’aste containing an organic sol- vent of low evaporation heat instead of hater.

The following method is available as ii iiiethd of uiiiizing rhe heat dis- charge. Iii the conventional drying ma- chine, a simple hood is provided at the upper part of a cylinder and discharge is effected by a fan. According to this arrangement, however, quantity of steam to be discharged is small and, theretore, it is necessary to raise the temperature of the dryer and to blow

Contents

23.8 m/m + 20.2 Tape width 11 m/m Tin roller + pulley 355 m/m# + 335

Effect

A 13.28 KW/Bale A 13.20 ,I

A 9.83 1 1

A 3.41 ** A 10.35 1 s

A 10.09 A 18.25 8 ,

hot air upon warp which is leaving the cylinder so as to accelerate evaporation heat. For this purpose, it comes under consideration to re-circulate the dis- charged air into a drying machine, to collect heat by using a heat-exchanger or to collect energy by a pump. Besides, various automatic devices such as a speed controller and a temperature controller for keeping the moisture content of dried warp constant are used practically.

At any rate, energy-saving in the siz- ing process should be taken into con- sideration from the aspect of totality of the improvement of weavability, saving of sizing material cost, etc. and should not be considered from the mere saving of energy for sizing. 2) Loom

Shuttle looms which have been equipped heavily of late due to speed- up, automation, etc. use a motor of larger capacity. However, since no change is made in the fundamental mechanism. any appreciable energy- saving has been realized for the shuttle loom. As 77% of the total energy con- sumed by the loom is shared by picking and beating, it is under study to store energy by spring for picking. Besides, use of bearing for crank shaft, lighter weight oflathe and the soft picking sys- tem are employed practically.

Shuttleless looms are available in many types and it is difficult to make comparison of them but in respect of electric- power required for weft insert- ing or picking per unit, the water-jet loom requires the least electric power. This comparison, however, does not in- voive energy required for drying wet woven fabric. At some of the weaving mills which are connected to dyeing mills, free length of woven fabric is made longer so that woven fabric dries naturally to such an extent that no trouble is caused in dyeing.

Consumption of energy by the jet loom, whether air type or water type,

I Electric power required for production of 1 bale

Power saving quantity and rate to 520 KW/l bale

60.22 KW (1 1.6%)

18.41 KW/Bale (15.1%)

18.25 (3.5%)

depends upon how to prevent spreading of jet in jetting. Therefore, studies on this point will be made harder in future.

In the case of rapier loom, it is under study to decrease the frictional resist- ance of rapiers and to make the weight of lathe lighter.

In general, the speed increase at high-speed revolution is proportional to the square of power consumption. It will therefore be advisable to hold the revolution speed to the lowest possible and to increase the width of loom the more. Since the motor consumes, even when it is idling, about 60% of electric power consumed at full-load running, makers are making efforts for manu- facturing such looms which cause less yarn breakage and less machine trou- ble. For weavers it is important to real- he energy-saving by decreasing stand- ing looms, by rectifying any abnormal loom through constant inspection of the motor and by keeping a check on air conditioning and lighting.

4. Energy-saving measures at dye-

‘The distribution ratio of cost at gen- eral woven fabric processing mills in Japan at the present time is as shown in the following table. Its characteristic lies in the fuel cost (putting aside the personnel expenses) which exceeds the dyestuff cost due to the rise in crude oil

ing process

price and ranks first in material costs. The textile industry which had been

making it5 way with labor-saving as the tirst target has encountered the knotty problem of energy-saving and the energy-saving is of urgent necessity for the industry.

The results of energy-saving activities executed for the last several years in the industry are as shown by the following table.

The above figures in the table are ex- tracted ti-om MITl (Ministry of Inter- national Trade and Industry) statistics

64 JTN, May. 1981

7 on the field of general woven fabrics (cxcepting woolen fabrics). Increases in power consumption may be attributa- ble mainly to the investment made in environmental pollution preventing fa- cilities.

There are no accurate statistics avail- able to clarify the improvements which contributed to the decrease of heavy oil consumption but such phenomenon will probably be ascribed to the follow- ing points.

In the aspect of software - Shorten- ing of process, rationalization

In the aspect of hardware - Elimi- nation of heat loss and collection of heat for reuse

r

Dyestuff cost 15%

Labor cost 35%

Electricity cost 5% Others 11%

100%

Chemicals cost 16%

Fuel cost 18%

c

- 1974

duce an immediate effect. Those niachines and processes whit

are in the stage of examination for a tual use are as tollows:

111 thc aspect of software, Cold batch bleaching Cold batch dyeing Form dyeing process

Besides, the dyeing system utilizit micro-wave has been developed as new technique.

In the aspect of hardware, Low-liquid dyeing machine Wince, water-jet dyeing machit

Burning mechanism, similar to tt closed system. which can minimize e. haust in burning at baking machir and heat setter which consume a larj quantity of fuel.

In addition to the above, improvc ments are being made in detail on tl. machines which use heat and mal kinds of energy-saving machines ha been introduced. Concrete functions these new machines will be introdua later. I n short, it may be said that tl method of energy-saving is multilater and comprehensive and can produce great effect only by coping with the tlo of heat individually and comprehe~ sively.

Power consumption Heavy oil consumption

0.1451 100 0.1936 100

KWH/mJ woven fabric Index Litter/" woven fabric Index . . _____ _____

1975 0.1429 98.5

1977 1 0.1542 106.3 1978 0.1562 107.7 1979 0.1620 11 1.6

*1980 0.1574 108.5

1976 0.1462 100.8

Table 6 Method of collection and reuse

0.1831 94.6 0.1771 91.5 0.1736 89.7 0.1686 87.1 0.1631 84.3 0.1441 14.4

Consump tion -_I.-~___

a. Exhaust in burning Heat discharge boiler

Reuse for catalytic burning Heat setter Backing m!c

b. High-temperature exhaust 1 Boiler Heat setter Baking m/c

, Gaseous phase + 1 aqueous phase

By heat-exchanger Direct collection

c. Boiier biow d. Cooling water e. Warmdrain

Washer Dyeing machine By heat-exchanger

f. Steam drain Closed system Open system

1

Reuse ___ Use as steam Decrease of exhaust loss by utilizing circuiation in ma- chine

Utilization by lukewarm water 'upply system

- do - - do -

- do -

Collect directly into a can Collect as boiler supply water

CLOTH CURER SENSATIONAL,

OPERATE HAND CUTTER FOR EFFORTLESS PRESICION CUTTING OF SMALL LAYS

ECONOMICAL 81 EASY-TO

0 3 DIFFERENT KNIFE REPLACEABLE

0 KNIFE REVOLVES AGAINST A STATIONARY CARBIDE COUNTER KNIFE

0 INTERCHANGEABLE BASE

MICRON BASE EASY-TO-GRIP

"' PMC-1011 SYNCHRON BASE HEAVY-DUTY

ELECTRIC

F

8. EMC-1005LH LONG REACH HANDLE

MANUFACTURER

SUBREmD INC

14, DAlHOJl HIGASHINOCHO

TEL: (06) 2454750 MINAMI-KU, OSAKA, JAPAN.

TLX: 522-5316 J (SUPRENA)

JTN, May, 1981 65

I