Energy Conservation Potential in Textile Sector-Pakistan By Shafqat Ullah Programme Manager Programme for Industrial Sustainable Development (PISD) CPI & Royal Netherlands Embassy Initiative CPI Cleaner Production Institute

Key Areas of Concern Lack in knowledge (energy wastages and energy saving potential) Untrained and uneducated human resources Old, inefficient, discarded machines Lack in monitoring aptitude Inefficient in resource consumption (water, chemicals, energy) Improper maintenance and upkeep

Lack in knowledge (energy wastages and energy saving potential)

Untrained and uneducated human resources

Old, inefficient, discarded machines

Lack in monitoring aptitude

Inefficient in resource consumption (water, chemicals, energy)

Improper maintenance and upkeep

Resource Consumption Practices Resource Consumption (per Kg of Fabric Processed) Optimum Consumption Saving Potential % Water 100-400 liter 70-100 30-75 Electricity 0.5-2.0 kWh 0.5-1.0 Up to 50% Natural Gas 0.5-2.0 m 3 0.5-1.0 Up to 50% Steam 5-15 kg 5-8 Up to 47

Monitoring and Measurement Water consumption (Water flow meters) Steam consumption (steam flow meters) Gas consumption (already in practice) Electricity consumption (already in practice) Monitoring of process control parameters (Temperature, pH, concent. etc) Rs. 1.3/m 3 -C o (Rs. 7.0 million/year) Process benchmarking

Water consumption (Water flow meters)

Steam consumption (steam flow meters)

Gas consumption (already in practice)

Electricity consumption (already in practice)

Monitoring of process control parameters (Temperature, pH, concent. etc)

Rs. 1.3/m 3 -C o (Rs. 7.0 million/year)

Process benchmarking

Monitoring and Measurement Water Quality Product Quality Deterioration More washes More energy More chemical consumption Scale in the machine More blow downs Reverse Osmosis, Softeners, Filters

Water Quality

Product Quality Deterioration

More washes

More energy

More chemical consumption

Scale in the machine

More blow downs

Reverse Osmosis, Softeners, Filters

Electricity Vs Production Gas Vs Electricity Generation Graphical Presentation

Maintenance & Upkeep Placement/upkeep of steam traps (Savings-Rs. 40,000-50,000/year-trap) Payback 3 months Steam leakage control (Savings-Rs. 100,000/year-leak control) Payback 2 months Insulation of hot pipelines and surfaces (Savings-Rs. 4,000-5,000/year-m) Payback 6 months Maintenance of machines (optimum resource consumption, noise control) Steam and air distribution system (pressure drops due to bends, long pipe lengths, slope of the lines, condensate removal, temperature and pressure gauges)

Placement/upkeep of steam traps (Savings-Rs. 40,000-50,000/year-trap)

Payback 3 months

Steam leakage control (Savings-Rs. 100,000/year-leak control)

Payback 2 months

Insulation of hot pipelines and surfaces (Savings-Rs. 4,000-5,000/year-m)

Payback 6 months

Maintenance of machines (optimum resource consumption, noise control)

Steam and air distribution system (pressure drops due to bends, long pipe lengths, slope of the lines, condensate removal, temperature and pressure gauges)

Process/Machines Modification Countercurrent washing sequence (bleaching, mercerization, dyeing etc.) (Savings-Rs. 800,000-1,000,000/year-machine) Payback 1 months

Countercurrent washing sequence (bleaching, mercerization, dyeing etc.)

(Savings-Rs. 800,000-1,000,000/year-machine)

Payback 1 months

Process/Machines Modification Spring operated or automatic water shut off valves on water hoses or at machines inlets Oversized steam boilers (1 ft 2 heating surface area = 3 kg steam/hr)

Spring operated or automatic water shut off valves on water hoses or at machines inlets

Oversized steam boilers (1 ft 2 heating surface area = 3 kg steam/hr)

Recovery & Reuse Recovery of heat from hot wastewater (Heat exchanger) (Savings-Rs. 900,000-1,000,000/year) payback 6 months Recovery of heat from exhaust gases of steam and therm oil boilers, generators-Boiler exhaust gases (Economizer) (Savings-Rs. 1,800,000-2,000,000/year) Payback 6 months

Recovery of heat from hot wastewater (Heat exchanger)

(Savings-Rs. 900,000-1,000,000/year)

payback 6 months

Recovery of heat from exhaust gases of steam and therm oil boilers, generators-Boiler exhaust gases (Economizer)

(Savings-Rs. 1,800,000-2,000,000/year)

Payback 6 months

Recovery & Reuse Reuse of steam condensate as boiler feed water (Savings-Rs. 500,000-600,000/year) Payback 8 months Reuse of cooling water (compressor, pumps, therm oil boilers, chillers, jets) (Savings-Rs. 50,000-100,000/year) Payback 6 to 12 months Reuse of RO rejected water for washing of floors and containers Resource conservation Reuse of inter process washes (Desizing, scouring, bleaching, mercerization) Resource conservation (Energy and water) Reuse of waste streams (mercerization waste stream for scouring bath) Pollution reduction/resource conservation (Rs. 1,000,000/year)

Reuse of steam condensate as boiler feed water

(Savings-Rs. 500,000-600,000/year)

Payback 8 months

Reuse of cooling water (compressor, pumps, therm oil boilers, chillers, jets)

(Savings-Rs. 50,000-100,000/year)

Payback 6 to 12 months

Reuse of RO rejected water for washing of floors and containers

Resource conservation

Reuse of inter process washes (Desizing, scouring, bleaching, mercerization)

Resource conservation (Energy and water)

Reuse of waste streams (mercerization waste stream for scouring bath)

Pollution reduction/resource conservation (Rs. 1,000,000/year)

Compressed Air System 5% of electrical energy is converted into compressed air energy Screw type compressors are more energy efficient than piston type Air quality (Moisture and Temperature) Cooler air intake (2.7 o C drop in intake air temp, reduces 1% energy) Distribution system (Pressure Drop), air leakages Cleaning points (Large diameter pipelines, air guns) – Instead of 8.5 mm dia, use 6 mm dia hose

5% of electrical energy is converted into compressed air energy

Screw type compressors are more energy efficient than piston type

Air quality (Moisture and Temperature)

Cooler air intake (2.7 o C drop in intake air temp, reduces 1% energy)

Distribution system (Pressure Drop), air leakages

Cleaning points (Large diameter pipelines, air guns) – Instead of 8.5 mm dia, use 6 mm dia hose

Electrical Consumption Estimated Load Distribution Department Designed Load (kW) % Share Blow Room 275 5.7 Carding 385 8.0 Comber 70 1.5 Lap Former 25 0.5 Drawing 110 2.3 Simplex 115 2.5 Ring Frames 2050 42.8 Auto Cone & Comp. 375 7.8 Doubling 195 4.0 Air Conditioning 955 20.0 Power House 175 3.7 Lighting 55 1.2 Total 4,785 100

Process/Machines Modification Effective Utilization of Peak and Off Peak Hours Electricity Schedule WAPDA TOD Schedule Season Peak (Avg. Rs.4.61/kWh Off Peak (Avg. Rs. 3.62/kWh) Dec to Feb 5:00 pm to 9:00 pm Remaining 20 hours March to May 6:00 pm to 10:00 pm Remaining 20 hours June to August 7:00 pm to 11:00 pm Remaining 20 hours Sep to Nov 6:00 pm to 10:00 pm Remaining 20 hours

Process/Machines Modification Effective Utilization of Peak and Off Peak Hours Electricity Schedule Cleaning and Overhauling of Machines at Peak Hours Electricity consumption (kWh/month) 189,037 Peak hours charges (Rs/month) 871,460 Off peak hours charges (Rs/month) 684,314 Saving per month 187,146

Process/Machines Modification When main units are stopped, auxiliary units like filters and air conditioning units should also be stopped One set of machines are stopped but auxiliary units designed for full capacity remain in operation Machines run at partial loads Machines must produce for the 75% of the total time

When main units are stopped, auxiliary units like filters and air conditioning units should also be stopped

One set of machines are stopped but auxiliary units designed for full capacity remain in operation

Machines run at partial loads

Machines must produce for the 75% of the total time

Process/Machines Modification Oversized Motors/Efficient Motors Efficiency of oversized motors is not good – It needs frequent monitoring of load (volt, ampere, power factor) Oversized motors should be replaced with appropriate sized motors (Improved efficiency-Energy saving) Use of efficiency Class 1, Class 2 and Class 3 motors

Efficiency of oversized motors is not good – It needs frequent monitoring of load (volt, ampere, power factor)

Oversized motors should be replaced with appropriate sized motors (Improved efficiency-Energy saving)

Use of efficiency Class 1, Class 2 and Class 3 motors

Process/Machines Modification (Air Conditioning) Air requirement is not known (velocity by anemometer , duct area) Fan power α (Air Flow 3 ) i.e. By reducing air flow half, reduces fan power one eight Inverters can be placed on fans to change air flow FRP (Fiberglass Reinforced Plastic) are more energy efficient

Air requirement is not known (velocity by anemometer , duct area)

Fan power α (Air Flow 3 ) i.e. By reducing air flow half, reduces fan power one eight

Inverters can be placed on fans to change air flow

FRP (Fiberglass Reinforced Plastic) are more energy efficient

Process/Machines Modification (Heating) Gas heating is cheaper than electric heating Hot exhaust gases of generators and compressors can be used Generator cooling water can be used Steam can be used Infrared lamps can be used

Gas heating is cheaper than electric heating

Hot exhaust gases of generators and compressors can be used

Generator cooling water can be used

Steam can be used

Infrared lamps can be used