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