International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Performance optimization of thermal systems in textile industriesIOSR Journals
Energy consumption has been growing very rapidly due to population growth, rapid urbanization
and industrial development. For future planning, it is important to know the current specific energy
consumption and the energy intensity in order to estimate future energy consumption. In the industrial sector
especially in textile units’ large amount of energy wasted due to improper working and lack of energy saving
measures. In this study, the various measures that causes the main energy losses are investigated .In the textile
dyeing sector, the main processes are associated with steam in various proportions. For the steam production,
steam boilers of different types are used for different applications. The efficiency of the boiler varies from one
industry to other based on various parameters such as quality of the water, fuel used, blow down quantity, etc.
Steam traps are also having influence on the boiler efficiency. In the case of steam leakage the performance of
the system decreases as the consumption of fuel increases to produce more steam. Thus by adopting various
recovery methods we can reduce the energy losses and fuel consumption.
Research was conducted on various stove design (wood, charcoal, bricks) that could be potentially modified in stove for desired purpose. Of the stoves gasifiers and Rocket stoves were two of the core design for design work.
Performance optimization of thermal systems in textile industriesIOSR Journals
Energy consumption has been growing very rapidly due to population growth, rapid urbanization
and industrial development. For future planning, it is important to know the current specific energy
consumption and the energy intensity in order to estimate future energy consumption. In the industrial sector
especially in textile units’ large amount of energy wasted due to improper working and lack of energy saving
measures. In this study, the various measures that causes the main energy losses are investigated .In the textile
dyeing sector, the main processes are associated with steam in various proportions. For the steam production,
steam boilers of different types are used for different applications. The efficiency of the boiler varies from one
industry to other based on various parameters such as quality of the water, fuel used, blow down quantity, etc.
Steam traps are also having influence on the boiler efficiency. In the case of steam leakage the performance of
the system decreases as the consumption of fuel increases to produce more steam. Thus by adopting various
recovery methods we can reduce the energy losses and fuel consumption.
Research was conducted on various stove design (wood, charcoal, bricks) that could be potentially modified in stove for desired purpose. Of the stoves gasifiers and Rocket stoves were two of the core design for design work.
Fabrication and Performance Analysis of Downdraft Biomass Gasifier Using Suga...IJSRD
The process by which biomass can be converted to a producer gas by supplying less oxygen than actually required for complete combustion of the fuel is known as gasification. It is a thermo-chemical process and it is performed by a device known as gasifier. For executing the gasification experiments nowadays single throated gasifier uses sugarcane industry waste. In the present study we get to know that sugarcane briquettes are manufactured from residue of sugarcane which is used as a biomass material for the gasification process. Briquettes are formed by extruding the sugar which is extracted from the residue of sugarcane (bagasse) dried in the sun. Equivalence ratio, producer gas composition, calorific value of the producer gas, gas production rate and cold gas efficiency are certain grounds for estimating the performance of the biomass gasifier. The experiential results are compared with those reported in the literature.
Biomass is biological material derived from living, or recently living organisms. It most often refers to plants or plant-based materials which are specifically called lignocellulosic biomass.
BIOMASS GASIFICATION,gasification and gasifier.
A slide about biomass gasification including brief description about thermo-chemical conversion process and applications
Gasifi cation is a process in which combustible materials are partially oxi-dized or partially combusted. The product of gasifi cation is a combustible synthesis gas, or syngas. Because gasifi cation involves the partial, rather than complete, oxidization of the feed, gasifi cation processes operate in an oxygen-lean environment. As fi gure 1 indicates, the stoichiometric oxygen-to-coal ratio for combustion is almost four times the stoichiometric oxygen-to-coal ratio for gasifi cation of Illinois #6coal.
A short introduction to Gasification process and a brief description on various types of Gasifiers used in industries to obtain fuel and energy through this presentation.
References:-
1. http://www.enggcyclopedia.com/2012/01/types-gasifier/
2. https://en.wikipedia.org/wiki/Gasification
3. https://www.youtube.com/watch?v=GkHKXz3VaFg
4. https://www.google.co.in/
Performance Test on Mixed Refrigerant in Domestic RefrigeratorIJERA Editor
Refrigerator is a household appliance used to preserve the foods, vegetables, beverages at low temperature. Refrigerant is the blood of the refrigerator and it changes its phase to transfer heat for giving cooling effect inside the refrigerator. Generally many refrigerator works under the vapour compression cycle and it uses only one refrigerant. Each and every refrigerant used in the refrigerator must have disadvantages, to overcome this problem we use mixed refrigerant (two different refrigerants with different properties are mixed together). In this project combination of R600a (isobutane) and R134a (1, 1, 1, 2-tetrafluroethane) is selected as a mixed refrigerant. R600a have some good properties like zero ODP, zero GWP and high latent heat of vapourization and R134a is non-toxic, non-flammable, non-corrosive and zero ODP.
We looked at the data. Here’s a breakdown of some key statistics about the nation’s incoming presidents’ addresses, how long they spoke, how well, and more.
32 Ways a Digital Marketing Consultant Can Help Grow Your BusinessBarry Feldman
How can a digital marketing consultant help your business? In this resource we'll count the ways. 24 additional marketing resources are bundled for free.
My books- Hacking Digital Learning Strategies http://hackingdls.com & Learning to Go https://gum.co/learn2go
Resources at http://shellyterrell.com/emoji
Artificial intelligence (AI) is everywhere, promising self-driving cars, medical breakthroughs, and new ways of working. But how do you separate hype from reality? How can your company apply AI to solve real business problems?
Here’s what AI learnings your business should keep in mind for 2017.
Study: The Future of VR, AR and Self-Driving CarsLinkedIn
We asked LinkedIn members worldwide about their levels of interest in the latest wave of technology: whether they’re using wearables, and whether they intend to buy self-driving cars and VR headsets as they become available. We asked them too about their attitudes to technology and to the growing role of Artificial Intelligence (AI) in the devices that they use. The answers were fascinating – and in many cases, surprising.
This SlideShare explores the full results of this study, including detailed market-by-market breakdowns of intention levels for each technology – and how attitudes change with age, location and seniority level. If you’re marketing a tech brand – or planning to use VR and wearables to reach a professional audience – then these are insights you won’t want to miss.
Fabrication and Performance Analysis of Downdraft Biomass Gasifier Using Suga...IJSRD
The process by which biomass can be converted to a producer gas by supplying less oxygen than actually required for complete combustion of the fuel is known as gasification. It is a thermo-chemical process and it is performed by a device known as gasifier. For executing the gasification experiments nowadays single throated gasifier uses sugarcane industry waste. In the present study we get to know that sugarcane briquettes are manufactured from residue of sugarcane which is used as a biomass material for the gasification process. Briquettes are formed by extruding the sugar which is extracted from the residue of sugarcane (bagasse) dried in the sun. Equivalence ratio, producer gas composition, calorific value of the producer gas, gas production rate and cold gas efficiency are certain grounds for estimating the performance of the biomass gasifier. The experiential results are compared with those reported in the literature.
Biomass is biological material derived from living, or recently living organisms. It most often refers to plants or plant-based materials which are specifically called lignocellulosic biomass.
BIOMASS GASIFICATION,gasification and gasifier.
A slide about biomass gasification including brief description about thermo-chemical conversion process and applications
Gasifi cation is a process in which combustible materials are partially oxi-dized or partially combusted. The product of gasifi cation is a combustible synthesis gas, or syngas. Because gasifi cation involves the partial, rather than complete, oxidization of the feed, gasifi cation processes operate in an oxygen-lean environment. As fi gure 1 indicates, the stoichiometric oxygen-to-coal ratio for combustion is almost four times the stoichiometric oxygen-to-coal ratio for gasifi cation of Illinois #6coal.
A short introduction to Gasification process and a brief description on various types of Gasifiers used in industries to obtain fuel and energy through this presentation.
References:-
1. http://www.enggcyclopedia.com/2012/01/types-gasifier/
2. https://en.wikipedia.org/wiki/Gasification
3. https://www.youtube.com/watch?v=GkHKXz3VaFg
4. https://www.google.co.in/
Performance Test on Mixed Refrigerant in Domestic RefrigeratorIJERA Editor
Refrigerator is a household appliance used to preserve the foods, vegetables, beverages at low temperature. Refrigerant is the blood of the refrigerator and it changes its phase to transfer heat for giving cooling effect inside the refrigerator. Generally many refrigerator works under the vapour compression cycle and it uses only one refrigerant. Each and every refrigerant used in the refrigerator must have disadvantages, to overcome this problem we use mixed refrigerant (two different refrigerants with different properties are mixed together). In this project combination of R600a (isobutane) and R134a (1, 1, 1, 2-tetrafluroethane) is selected as a mixed refrigerant. R600a have some good properties like zero ODP, zero GWP and high latent heat of vapourization and R134a is non-toxic, non-flammable, non-corrosive and zero ODP.
We looked at the data. Here’s a breakdown of some key statistics about the nation’s incoming presidents’ addresses, how long they spoke, how well, and more.
32 Ways a Digital Marketing Consultant Can Help Grow Your BusinessBarry Feldman
How can a digital marketing consultant help your business? In this resource we'll count the ways. 24 additional marketing resources are bundled for free.
My books- Hacking Digital Learning Strategies http://hackingdls.com & Learning to Go https://gum.co/learn2go
Resources at http://shellyterrell.com/emoji
Artificial intelligence (AI) is everywhere, promising self-driving cars, medical breakthroughs, and new ways of working. But how do you separate hype from reality? How can your company apply AI to solve real business problems?
Here’s what AI learnings your business should keep in mind for 2017.
Study: The Future of VR, AR and Self-Driving CarsLinkedIn
We asked LinkedIn members worldwide about their levels of interest in the latest wave of technology: whether they’re using wearables, and whether they intend to buy self-driving cars and VR headsets as they become available. We asked them too about their attitudes to technology and to the growing role of Artificial Intelligence (AI) in the devices that they use. The answers were fascinating – and in many cases, surprising.
This SlideShare explores the full results of this study, including detailed market-by-market breakdowns of intention levels for each technology – and how attitudes change with age, location and seniority level. If you’re marketing a tech brand – or planning to use VR and wearables to reach a professional audience – then these are insights you won’t want to miss.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
WASTE HEAT RECOVERY TO INCREASE BOILER EFFICIENCY USING BAGASSE AS FUEL IAEME Publication
Many industrial heating processes generate waste energy in textile industry; especially exhaust gas from the boiler at the same time reducing global warming. Waste heat found in the
exhaust gas can be used to preheat the incoming gas. This is one of the basic methods for recovery of waste heat. Therefore, this article will present a study the way to recovery heat waste from boiler exhaust gas by mean of shell and tube heat exchanger.
Identification of Some of Low Temperature Waste Heat Utilization Potentials i...theijes
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The International Journal of Engineering & Science would take much care in making your article published without much delay with your kind cooperation
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Thermodynamic Analysis of Cooling Tower with Air to Air Heat Exchanger for Re...IJMREMJournal
In this paper a thermodynamic analysis of cooling tower with air-to-air heat exchanger is presented. During
manual operation of conventional cooling tower, a good quantity of water is evaporated which requires equivalent
amount of makeup water for their condensers. So, in this regard, the thermodynamic model of a cooling with an
air to air heat exchanger is developed using engineering equation solver (EES) software and then simulated in
different climatic conditions of two major cities of Pakistan namely Karachi and Jamshoro through the period of
June & December 2017. The results show a significant variation in water vapor recovery with respect to
atmospheric conditions mainly humidity and ambient air temperature. Results reveal that the when a cooling
tower coupled with air to air heat exchanger maximum amount of water vapors are recovered at Karachi and
ranges up to 67% and 62% in Jamshoro during the month of December.
Thermodynamic Analysis of Cooling Tower with Air to Air Heat Exchanger for Re...IJMREMJournal
In this paper a thermodynamic analysis of cooling tower with air-to-air heat exchanger is presented. During manual operation of conventional cooling tower, a good quantity of water is evaporated which requires equivalent amount of makeup water for their condensers. So, in this regard, the thermodynamic model of a cooling with an air to air heat exchanger is developed using engineering equation solver (EES) software and then simulated in different climatic conditions of two major cities of Pakistan namely Karachi and Jamshoro through the period of June & December 2017. The results show a significant variation in water vapor recovery with respect to atmospheric conditions mainly humidity and ambient air temperature. Results reveal that the when a cooling tower coupled with air to air heat exchanger maximum amount of water vapors are recovered at Karachi and ranges up to 67% and 62% in Jamshoro during the month of December.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
GraphRAG is All You need? LLM & Knowledge GraphGuy Korland
Guy Korland, CEO and Co-founder of FalkorDB, will review two articles on the integration of language models with knowledge graphs.
1. Unifying Large Language Models and Knowledge Graphs: A Roadmap.
https://arxiv.org/abs/2306.08302
2. Microsoft Research's GraphRAG paper and a review paper on various uses of knowledge graphs:
https://www.microsoft.com/en-us/research/blog/graphrag-unlocking-llm-discovery-on-narrative-private-data/
UiPath Test Automation using UiPath Test Suite series, part 4DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 4. In this session, we will cover Test Manager overview along with SAP heatmap.
The UiPath Test Manager overview with SAP heatmap webinar offers a concise yet comprehensive exploration of the role of a Test Manager within SAP environments, coupled with the utilization of heatmaps for effective testing strategies.
Participants will gain insights into the responsibilities, challenges, and best practices associated with test management in SAP projects. Additionally, the webinar delves into the significance of heatmaps as a visual aid for identifying testing priorities, areas of risk, and resource allocation within SAP landscapes. Through this session, attendees can expect to enhance their understanding of test management principles while learning practical approaches to optimize testing processes in SAP environments using heatmap visualization techniques
What will you get from this session?
1. Insights into SAP testing best practices
2. Heatmap utilization for testing
3. Optimization of testing processes
4. Demo
Topics covered:
Execution from the test manager
Orchestrator execution result
Defect reporting
SAP heatmap example with demo
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
The publishing industry has been selling digital audiobooks and ebooks for over a decade and has found its groove. What’s changed? What has stayed the same? Where do we go from here? Join a group of leading sales peers from across the industry for a conversation about the lessons learned since the popularization of digital books, best practices, digital book supply chain management, and more.
Link to video recording: https://bnctechforum.ca/sessions/selling-digital-books-in-2024-insights-from-industry-leaders/
Presented by BookNet Canada on May 28, 2024, with support from the Department of Canadian Heritage.
Kubernetes & AI - Beauty and the Beast !?! @KCD Istanbul 2024Tobias Schneck
As AI technology is pushing into IT I was wondering myself, as an “infrastructure container kubernetes guy”, how get this fancy AI technology get managed from an infrastructure operational view? Is it possible to apply our lovely cloud native principals as well? What benefit’s both technologies could bring to each other?
Let me take this questions and provide you a short journey through existing deployment models and use cases for AI software. On practical examples, we discuss what cloud/on-premise strategy we may need for applying it to our own infrastructure to get it to work from an enterprise perspective. I want to give an overview about infrastructure requirements and technologies, what could be beneficial or limiting your AI use cases in an enterprise environment. An interactive Demo will give you some insides, what approaches I got already working for real.
Builder.ai Founder Sachin Dev Duggal's Strategic Approach to Create an Innova...Ramesh Iyer
In today's fast-changing business world, Companies that adapt and embrace new ideas often need help to keep up with the competition. However, fostering a culture of innovation takes much work. It takes vision, leadership and willingness to take risks in the right proportion. Sachin Dev Duggal, co-founder of Builder.ai, has perfected the art of this balance, creating a company culture where creativity and growth are nurtured at each stage.
Dev Dives: Train smarter, not harder – active learning and UiPath LLMs for do...UiPathCommunity
💥 Speed, accuracy, and scaling – discover the superpowers of GenAI in action with UiPath Document Understanding and Communications Mining™:
See how to accelerate model training and optimize model performance with active learning
Learn about the latest enhancements to out-of-the-box document processing – with little to no training required
Get an exclusive demo of the new family of UiPath LLMs – GenAI models specialized for processing different types of documents and messages
This is a hands-on session specifically designed for automation developers and AI enthusiasts seeking to enhance their knowledge in leveraging the latest intelligent document processing capabilities offered by UiPath.
Speakers:
👨🏫 Andras Palfi, Senior Product Manager, UiPath
👩🏫 Lenka Dulovicova, Product Program Manager, UiPath
Elevating Tactical DDD Patterns Through Object CalisthenicsDorra BARTAGUIZ
After immersing yourself in the blue book and its red counterpart, attending DDD-focused conferences, and applying tactical patterns, you're left with a crucial question: How do I ensure my design is effective? Tactical patterns within Domain-Driven Design (DDD) serve as guiding principles for creating clear and manageable domain models. However, achieving success with these patterns requires additional guidance. Interestingly, we've observed that a set of constraints initially designed for training purposes remarkably aligns with effective pattern implementation, offering a more ‘mechanical’ approach. Let's explore together how Object Calisthenics can elevate the design of your tactical DDD patterns, offering concrete help for those venturing into DDD for the first time!
Smart TV Buyer Insights Survey 2024 by 91mobiles.pdf91mobiles
91mobiles recently conducted a Smart TV Buyer Insights Survey in which we asked over 3,000 respondents about the TV they own, aspects they look at on a new TV, and their TV buying preferences.
1. Sherin K M et al. Int. Journal of Engineering Research and Application www.ijera.com
Vol. 3, Issue 5, Sep-Oct 2013, pp.324-328
www.ijera.com 324 | P a g e
Potential of Waste Heat Recovery in Textile Industries
Sherin K M*, M G Prince**
*(PG Scholar, MES College of Engineering, Calicut University, Kerala
** (Assistant professor, Department of Mechanical Engineering, MES College of Engineering, Kerala
ABSTRACT
Many developing countries, including India, look forward to developing strong integrated textile industries to
add value to already-available raw materials. Textile industry is one of the largest industries, which consumes
energy in the form of heat. Dyeing and finishing activities are, however, energy-intensive. In many cases, these
depend on imported fossil fuels. By turning to heat recovery, significant cost savings can be achieved improving
profitability and competitiveness. New technologies are required to recover some percentage of loss of energy.
The techniques and technologies of heat recovery from boiler blow down, condensate and waste water are
analyzed. Waste heat utilization in the textile industry is gaining vital importance in the Indian textile industry as
international legislations are also to come into force in our country. This paper focuses on potential of heat
recovery has brought significant cost reduction in textile dyeing and processes. The focus is on steam utilization
in textile mills. The paper includes case studies from various textile dyeing plants in Tirupur area of TamilNadu.
Keywords – Boiler blow down, Condensate recovery, Steam utilization, Textile industry, Waste water.
I. INTRODUCTION
Textile process industries are those industries
where the primary production processes are either
continuous, or occur on a batch of materials that is
indistinguishable. Textiles (dyeing and printing) are
energy intensive industries. In the face of rising costs
and increased competition, efficient utility
management is a major focus area in these industries.
One of the textile manufacturing clusters in India is
located in Tirupur district of TamilNadu. Over 100
units of dyeing plants are integrated with textile
processes. Steam is used as energy carrier for
processing applications like dyeing and finishing in all
textile industries. Hence boilers are the main fuel
consumers in the textile industries in Tirupur area.
Cost of fuel for generating Steam in the meantime
continued to grow steeply, nearly offsetting the
benefits of reductions achieved in other areas[1].
In this paper, the major heat recovery areas
were found to be in boiler blow down, condensate and
waste water that is drained after the dyeing process. A
study conducted in textile sector Tirupur district of
Tamil Nadu to generalize the direct impact of boiler
blow down, condensate and waste water heat recovery
on fuel consumption. As a part of study, energy and
mass balance is performed on boiler and calculated the
amount of energy can save through recovering the heat
from boiler blow down, condensate recovery and
waste water that is disposed to sewage. In all the
industries, their main investment is in the steam
production. As the industrial sector continues efforts
to improve its energy efficiency, recovering waste heat
losses provides an attractive opportunity for an
emission free and less costly energy resource.
II. AREAS OF WASTE HEAT RECOVERY IN
TEXTILE INDUSTRIES.
The main areas of waste heat recovery in
textile dyeing are from boiler blow down flash steam,
hot condensate flash steam and heat recovery from
processed waste water.
III. BOILER BLOW DOWN HEAT
RECOVERY
As water evaporates in the boiler steam drum,
solids present in the feed water are left behind. The
suspended solids form sludge or sediments in the
boiler, which degrades heat transfer. Dissolved solids
promote foaming and carryover of boiler water into
the steam. To reduce the levels of suspended and total
dissolved solids (TDS) to acceptable limits, water is
periodically discharged or blown down from the
boiler. Mud or bottom blow down is usually a manual
procedure done for a few seconds on intervals of
several hours. It is designed to remove suspended
solids that settle out of the boiler water and form a
heavy sludge. Surface or skimming blow down is
designed to remove the dissolved solids that
concentrate near the liquid surface. Surface blow down
is often a continuous process[2].
Minimizing blow down rate can substantially
reduce energy losses, as the temperature of the blown-
down liquid is the same as that of the steam generated
in the boiler. Minimizing blow down will also reduce
makeup water and chemical treatment costs.
Insufficient blow down may lead to carryover of boiler
water into the steam, or the formation of deposits.
Excessive blow down will waste energy, water, and
chemicals.
RESEARCH ARTICLE OPEN ACCESS
2. Sherin K M et al. Int. Journal of Engineering Research and Application www.ijera.com
Vol. 3, Issue 5, Sep-Oct 2013, pp.324-328
www.ijera.com 325 | P a g e
It is necessary to control the level of
concentration of the solids and this is achieved by the
process of 'blowing down', where a certain volume of
water is blown off and is automatically replaced by
feed water - thus maintaining the optimum level of
total dissolved solids (TDS) in the boiler water. Blow
down is necessary to protect the surfaces of the heat
exchanger in the boiler. However, blow down can be a
significant source of heat loss, if improperly carried
out.
3.1. Concept of flash steam
Flash steam is vapor or secondary steam
formed from hot condensate discharged into a lower
pressure area. It is caused by excessive boiling of the
condensate which contains more heat than it can hold
at the lower pressure. Flash steam occupies many
times the volume of water from which it forms. For
example, flash steam created by hot condensate
flowing from 15 PSIG to an atmospheric pressure will
have nearly 1,600 times the volume of the high
pressure hot water[3].
If the pressure is increased both the boiling
point and the heat content at boiling go up.
Conversely, if the pressure of the boiling water is
reduced, the water must reduce its temperature and
heat content to those corresponding to the lower
pressure. This means that a certain amount of heat
must be released, and this excess heat will be absorbed
in the form of latent heat, causing part of the water to
flash into steam[3].
%Flash = hf@high pressure- hf@low pressure x 100
hfg @ low pressure (1)
Where hf@high pressure is pressure at which the
boiler operates, hf@lower pressure is the pressure at
which the boiler blown takes place, i.e. at atmospheric
pressure and hfg@lower pressure is the latent heat in
the atmospheric pressure.
Heat content in the flash steam from Boiler
blow down and condensate can be recovered back to
pre heat the boiler feed water and Flash steam
produced due to excess boiler blow down also can
reduced fuel consumption rate.
The blow down performed on a boiler when
it’s under working; hence the blow down water is at
boiler temperature and pressure. It contains large
quantity of energy. For a particular amount of blow
down water to reach that temperature boiler has to
supply certain amount of fuel. Hence in all respect the
blow down is fuel wastage[4]. But for efficient
operation of boiler it’s necessary.
Table 3.1 Fuel wastage in Industries
Industry Blow down
rate(kg/day)
Amount of
Fuel
wasted(kg/day)
G.K.M PROCESS 4848 147.37
JAI KNIT 1680 51.07
M.S DYEING 5724 147
MICRO KNIT 2862 76.43
P.R.N PROCESS 2016 61.28
PEACOCK 2520 49.28
RAAGAM 4320 115.37
SUGAN 1872 41.63
T.B.S DYEING 5040 98.56
VARSHAN 1800 47.23
From the audit conducted in 10 textile
processing unit it is observed that nearly 3% of total
fuel consumption is wasted through blow down. i.e.,
nearly a 850Kg of fuel (wood) is wasted as blow
down, which is equivalent to a price value of
3000rs/day. In actual blow down losses may includes
the makeup water cost and its treatment cost.
Figure 3.1 Variations in fuel consumption with blow
down recovery.
It is found that Flash steam recovery from the
boiler blow down also increases the efficiency of the
boiler up to 2%. Heat recovery is used frequently to
reduce energy losses that result from boiler water blow
down.
3. Sherin K M et al. Int. Journal of Engineering Research and Application www.ijera.com
Vol. 3, Issue 5, Sep-Oct 2013, pp.324-328
www.ijera.com 326 | P a g e
Figure 3.2 Changes in the boiler efficiencies.
It is found that boiler efficiency has
significantly improved after flash stem recovered from
the boiler blow down. Installation of heat recovery
equipment is valuable only when energy from the flash
tank or the blow down water can be recovered and
utilized. In flash recovery system, the blow down
water is directly supplied to a flash vessel which is at
atmospheric pressure. Due to the change in enthalpies
of water at boiler pressure and atmospheric pressure
nearly 13% of blow down water is converted into flash
steam. This steam is directly supplied to the feed water
tank hence the temperature of feed water is raised due
to high enthalpy value of steam. The flash steam
contains nearly 49% of energy contained in the blow
down water.
Table 3.2Fuel savings by blow down recovery.
Industry
Savings in Fuel
Monitory
savings
(Rs/annum)(Kg/day) (Tons/
annum)
G.K.M
PROCESS
147.38 39 1,29,000
JAI KNIT 51.07 12.8 44800
M.S DYEING 147 36.7 129000
MICRO
KNIT
76.43 19 66500
P.R.N
PROCESS
61.28 15.3 53500
PEACOCK 49.28 12.3 43000
RAAGAM 115.37 29 101500
SUGAN 41.63 10.4 36400
T.B.S
DYEING
98.56 24.6 86100
VARSHAN 47.23 11.8 41300
From the analysis carried out in industries its found
that 3% of fuel can be saved through flash stem from
the blow down.
With every 6% rise in the temperature of feed water it
is observed that a 1% reduction in the wood
consumption. Reduction in wood consumption means
that the increased efficiency of boiler. From the
analytical comparison between the system with heat
recovery and without heat recovery, it is observed that
the efficiency of boiler if nearly 3% rise.
IV. CONDENSATE HEAT RECOVERY
Steam contains two types of energy: latent
and sensible. When steam is supplied to a process
application (heat exchanger, coil, etc.) the steam vapor
releases the latent energy to the process fluid and
condenses to a liquid condensate. The condensate
retains the sensible energy the steam had. The
condensate can have as much as 16% of the total
energy in the steam vapor, depending on the
pressure[5].
One of highest return on investments is to
return condensate to the boiler. As fuel costs continue
to rise, it’s imperative to focus on recovering
condensate in every industrial steam operation.
Returning hot condensate to the boiler makes sense for
several reasons. As more condensate is returned, less
make-up water is required, saving fuel, makeup water,
and chemicals and treatment costs. Less condensate
discharged into a sewer system reduces disposal costs.
Return of high purity condensate also reduces energy
losses due to boiler blow down.
2.2.1 Flash steam recovery
Condensate is discharged through traps from
a higher to a lower pressure. As a result of this drop in
pressure, some of the condensate will then re-
evaporate into 'flash steam. The flash steam generated
can contain up to half of the total energy of the
condensate, hence flash steam recovery is an essential
part of an energy efficient system[5].
% flash steam= (SH-SL)/H*100 (2)
Where SH = Sensible heat in the condensate at the
higher pressure before discharge, SL = Sensible heat
in the condensate at the lower pressure to which
discharge takes place and H = Latent heat in the steam
at the lower pressure to which the condensate has been
discharged.
In the industries, it is found that the hot condensate is
discharges to sewage without recovering its energy.
The amount of condensate and flash steam produced in
each industry is given in table.
4. Sherin K M et al. Int. Journal of Engineering Research and Application www.ijera.com
Vol. 3, Issue 5, Sep-Oct 2013, pp.324-328
www.ijera.com 327 | P a g e
Table 4.1 Amount of condensate formed
Industry Total
steam
product
ion
(kg/day
)
Amount
of
condensa
te
formed
(kg/day)
Amount
of flash
steam
recovere
d
(kg/day)
G.K.M
PROCESS
2145.6 2072 210.41
JAI KNIT 1992 1760 178.74
M.S DYEING 4282.8 3267 236.88
MICRO KNIT 2138 1615 219.32
P.R.N
PROCESS
1984 1813 184.07
PEACOCK 3744 2697 289.76
RAAGAM 2904 2401 243.79
SUGAN 938.4 634 58.12
T.B.S DYEING 1480 1133 121.85
VARSHAN 2200 1872 171.69
From the audit conducted in 10 textile
processing unit it is observed that nearly 2% of total
fuel consumption is wasted through condensate
drainage. i.e., nearly a 400kg fuel is wasted per day,
which can be saved thorough proper condensate
recovery method.
Table 4.2Fuel savings by Condensate flash steam
recovery.
Industry
Savings in Fuel
Monitory
savings
(Rs/annum)(Kg/day) (Tons/
annum)
G.K.M
PROCESS
42.02 10.5 36750
JAI KNIT 35.7 9 31500
M.S DYEING 47.31 11.8 41300
MICRO
KNIT
43.80 11 38500
P.R.N
PROCESS
36.76 9.2 32200
PEACOCK 57.87 14.5 50750
RAAGAM 48.69 12.2 42700
SUGAN 11.6 2.9 10150
T.B.S
DYEING
24.33 6 21000
VARSHAN 36.57 9.2 32200
As per the study conducted, the textile
industry inTirupur-TamilNadu has been consumed
about 96.3 T of wood per annum for steam generation.
Through condensate and flash steam recovery, the
potential reductions in fuel consumption reduce and
also raise the temperature of feed water to 80-900
. The
impact of heat recovery on boiler fuel consumption in
textile plant is shown fig 4.1.
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Fuel consumption
Without Condensate recovery
With Condensate recovery
Figure 4.1 Impact on fuel consumption
Based on detailed studies carried in
industries, some of the boilers were found to be
inefficient and the efficiencies were found to be range
of 40 to 80%. 0n recovering the flash steam from
condensate remarkably enhances the boiler efficiency
by 1%[6] .
0
10
20
30
40
50
60
70
80
90
G.K.MPROCESS
JAIKNIT
M.SDYEING
MICROKNIT
P.R.NPROCESS
PEACOCK
RAAGAM
SUGAN
T.B.SDYEING
VARSHAN
efficiency(%)
Boiler efficiency
Figure 4.2 Changes in the boiler efficiencies.
It is clear that, flash steam recovery from hot
condensate enhanced boiler efficiency and it will in
turn reduce the fuel consumption rate.
The return of condensate represents huge potential for
energy savings in the boiler house. Condensate has
high heat content and approximately 1% less fuel is
required for every 6°C temperature rise in the feed
5. Sherin K M et al. Int. Journal of Engineering Research and Application www.ijera.com
Vol. 3, Issue 5, Sep-Oct 2013, pp.324-328
www.ijera.com 328 | P a g e
tank. The more the condensate recovery, the lesser will
the condensate that is discharged into a sewer system
be and the lower will the blow down be. This will
reduce the sewer disposal costs.
V. HEAT RECOVERY FROM WASTE
WATER
Batch or non-continuous processing is
common in textile dyeing plants. Thus, a large volume
of wastewater is available intermittently from several
machines at different locations in the plant. If
wastewater can neither be re-used nor can its heat be
recovered locally, the feasibility of installing a
centralized heat recovery system should be
investigated[7].
Equipment such as washing-, mercerizing-
and bleaching-machines often operate continuously for
long hours, requiring a large volume of hot water and
produce an equal volume of hot waste water
simultaneously. A characteristic feature of some
technology is the incorporation of heat exchangers on
such textile machines with the purpose of heating up
the incoming cold-water stream with hot wastewater
leaving the machine.
In the industries that study has done, the
amount waste/processed water is simply dumped to
sewage. If it is properly utilized for preheating the
boiler feed water or dyeing purpose, it can save energy
as well as water.
0
1000
2000
3000
4000
5000
6000
7000
8000
G.K.MPROCESS
JAIKNIT
M.SDYEING
MICROKNIT
P.R.NPROCESS
PEACOCK
RAAGAM
SUGAN
T.B.SDYEING
VARSHAN
waterquqntity(kg/day)
Figure 5.1 Amount of waste water.
Hot wastewater, produced in textile dyeing
plats, can be a significant source of heat energy. In
many instances, this valuable resource is discharged to
wastewater treatment facilities without employing the
heat it acquired during processing. The waste water
quantity has been calculated by the equation,
Q = mwater Cp t (3)
Where Q is the quantity of energy absorbed in kcals,
mwater is the amount of waste water ( in kg) , Cp is the
specific heat of water in( kcals/kg 0
C) and t is the
temperature rise of the substance (in 0
C).
Most of the heat contained in the wastewater stream
can be reclaimed and utilized, while providing
significant cost reductions with attractive payback
periods. Through utilization of proper wastewater heat
recovery system, reclaimed heat from the wastewater
discharge can preheat incoming process water; thereby
saving fuel costs, while enhancing the environment
through the removal of thermal pollution.
VI. CONCLUSION
Evaluating the feasibility of waste heat
recovery requires characterizing the waste heat source
and the stream to which the heat will be transferred.
Important waste stream parameters that must be
determined include: heat quantity, heat
temperature/quality, composition, minimum allowed
temperature, and• operating schedules, availability,
and other logistics. These parameters allow for
analysis of the quality and quantity of the stream and
also provide insight into possible materials/design
limitations.
By implementing the waste heat recovery
methods we can conserve the energy in the textile
industries. The improvements in the boiler blow down,
condensate recovery, feed water management and
waste water recovery will minimize the energy losses
and improve the performance of the thermal systems
in textile industries.
As the industrial sector continues efforts to
improve its energy efficiency, recovering waste heat
losses provides an attractive opportunity for an
emission free and less costly energy resource.
REFERENCES
[1] G.F.Hewitt, G.L.Shires and T.R.Bott,
“Process Heat Transfer”, CRC Press, Boca
Rato, FL, 1994.
[2] Bureau of Energy Efficiency. Energy
Efficiency in Thermal Utilities. Book 2, 2004
[3] Barclay, S.; Buckley, C., 2000. Waste
Minimization Guide for the Textile Industry.
[4] The Steam and Condensate Loop Book.
Spirax and sarco.
[5] Industrial Energy Conservation by Melvin
H.Chiogioji, Marcel Dekker Inc, 1979, New
York.
[6] Elahee M. K., (2001). Energy Management:
Optimisation of the use of steam in the textile
industry in Mauritius, PhD thesis, Faculty of
Engineering, University of Mauritius.
[7] Fundamentals of Steam Boilers & Pressure
Vessel Inspection Techniques by Homi
P.Seervai, Macmillan Company of India Ltd,
New Delhi, 1974.