The document outlines the use of steam in the textile industry, emphasizing the importance of efficient boiler systems and energy-saving measures such as parameter optimization, insulation, economizers, and burner controls. It discusses practical examples demonstrating potential energy and cost savings, such as the installation of a vapor condenser for feed water heating. Overall, the implementation of advanced control systems and maintenance practices is recommended to minimize energy waste and improve operational efficiency.

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Overview
 Introduction
 Use of steam in the textile industry
 Theory/Measures
 Boiler
 Parameter optimization
 Insulation
 Economizer
 Condensate, feed water
 Burner control
 Exercises
 Summary
Introduction - Theory - Exercises - Business Case - Summary

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Introduction.
Introduction - Theory - Exercises - Business Case - Summary

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Use of steam in
the textile industry
• One of the heat transfer medium in the
textile industry (beside thermal oil, hot
water and air)
• In clarifications, energy is used to a
great extent for steam production

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Theory.

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Measures
• Boiler
• Parameter optimization
• Insulation
• Economizer
• Condensate, feed water
• Burner control
Introduction - Theory - Exercises - Business Case - Summary

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Boiler
• Preparation of the steam through central boiler
• Applied boilers often aged15-20 years
• New models with automatic control and efficient
periphery have less waste of energy
• As a consequence of changes in production and
already implemented measures, boiler are often
oversized
• The decreased boiler utilization leads to an
unfavourable control behaviour, energy losses, a
greater wear and increased refurbishment
expenditures
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• Problem: The developed pressures or
temperatures frequently do not
immediately comply with the respective
needs of the consumers, which leads to
losses during generation and distribution
of heating
• Corrective: Decrease of the pressure
level; decentralized supply of individual
plants at high temperature and pressure
Parameter optimization
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Insulation
• On fittings, valves and flange
joints: Use of specific
insulation sleeves, which can
easily be removed and
replaced.
• Subsequent heat insulation
may be appropriate (for
example dyeing apparatus)
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Economizer
• Problem: Large heat losses
through high exhaust-gas
temperatures on the boiler
• Economizer: Heating of the
feed water through cooling of
the flue gas from the boiler
• Alternative: Exhaust gas blower
for automatic venting
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Condensate and feed water
• To prevent heat losses, steam traps
• Shall be regularly reviewed or changed
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• Measure: Use of a O2 burner control system on
steam boilers
• Effect: Air-surplus during the firing-process and
therefore die heat loss through exhaust gas can be
reduced to the minimal necessary value. Potential
savings: 1,5 % of the purchased fuel energy
• Furthermore, flame fresh air can be heated up
through the integration of existing heat sources
• Pre-heating of the combustion air on burners of
central boiler as well as decentralized heat
producers (for example tensioning frames, dryer)
Burner control

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Exercises.
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Why have new boiler a less
waste of energy? Because of
the…
a. …automatic control
and efficient periphery
b. …use of renewable
energy Introduction
Boiler
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Why have new boiler a less
waste of energy? Because of
the…
a. …automatic control
and efficient periphery
b. …use of renewable
energy Introduction
Boiler
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What are the potential savings
of the purchased fuel energy?
a. 1,5 %
b. 10,5 %
Burner control
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What are the potential savings
of the purchased fuel energy?
a. 1,5 %
b. 10,5 %
Burner control
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What is the utility of economizer?
a. Decrease of the pressure level
b. Heating of the feed water
through cooling of the flue gas
rom the boiler
Economizer
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What is the utility of economizer?
a. Decrease of the pressure level
b. Heating of the feed water
through cooling of the flue
gas from the boiler
Economizer
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Gap text
Enter the correct, missing word
As a consequence of changes in production
and already implemented measures, boiler are
often _________.
oversized rusted messy
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Gap text
Enter the correct, missing word
As a consequence of changes in production
and already implemented measures, boiler are
often _________.
oversized rusted messy
Introduction - Theory - Exercises - Business Case - Summary

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Business Case.
Introduction - Theory - Exercises - Business Case - Summary

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Heat recovery at the feed
water tank
Introduction - Theory - Exercises - Business Case - Summary
• Practical example:
To reduce the heat loss, due to escaping steam at the
feed water tank, a vapour condenser was installed in a textile company,
for feed water heating
condensate
fresh water
feed water
balance room
ramp metering
pressure
compensation
heating steam
feed water storage tank
vent condenser

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Issue Cost/ savings
Investment 35.000 €
Fuel saving 390 MWh/a HS
Cost savings 17.500 €/a
Carbone dioxid savings 70 t /a
Heat recovery at the feed
water tank
Introduction - Theory - Exercises - Business Case - Summary
Source: Energie Agentur.NRW (2012): Leitfaden. Effiziente Energienutzung in der Textilveredlung.

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Summary.
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• Steam is one of the heat transfer media in the
textile industry
• Preparation of the steam through central boiler;
new models with automatic control and
efficient periphery have less waste of energy
• On fittings, valves and flange joints, the use of
specific insulation sleeves is recommended
• Flame control through the use of a O2 burner
control system on steam boilers can effect
savings up to 1,5 % of the purchased fuel
energy
• Condensate and feed water prevents heat
losses and steam traps
Repetition
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Readings
[1] Energie Agentur.NRW (2012): Leitfaden. Effiziente Energienutzung in der
Textilveredlung. http://www.zitex.de/uploads/media/BEK_Textil_Leitfaden_final.pdf
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Pictures-1
 Slide 1
Justin Russell: Illuminated steam
URL: https://www.flickr.com/photos/nightthree/3588328/sizes/z/in/photolist-joFJ-dqrzDJ-b4qSAM-jqG5CK-fnMzhT-6VfKbh-9qS9aH-8Cdd95-
dvtdFK-9a44W-9a3TK-fnMRbM-fo1xMy-fo4f6E-fo2Enw-fnMs2T-fo2H4Q-8e81rC-fwpWxC-9a43q-fFPPH1-7HqeXx-nyGyoj-dRuUf-6nPvej-foygyD-
mUN1Xc-mUQ2m3-283wS-9xUrSq-foyU7M-foP6jh-bKoya6-foP899-6STKdz-nqe3Sa-fnP3YR-4S9qD-fnMJ1i-dFGAZ9-5Dt8cX-hnNGJ-foyS7K-foyL2x-
foP5jf-foP4sf-fnSkzm-goDoN4-6SXMd1-5AyGi4/
Licence: CC BY 2.0 (https://creativecommons.org/licenses/by/2.0/deed.de)
• Slide 2
reflex477: Overview over Paris from Sacré-Cœur –
URI: http://www.flickr.com/photos/35164559@N04/4223238879/sizes/m/in/photostream/
License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
• Slide 3
Simon Carr: Steam from old city hall
URL: https://www.flickr.com/photos/simoncarr/6743653889
License: CC BY-SA 2.0 (https://creativecommons.org/licenses/by-sa/2.0/deed.de)
• Slide 4
Karl Frankowski: Midnight at the Steam Plant
URL: https://www.flickr.com/photos/karlfrankowski/312093270/in/photolist-tzyss-bQ2Rxn-bgUWLz-cUJWpo-5AifNW-aGggfB-euBnfV-9a3Hx-
4Ai1Ec-6pR3jy-cUJRVf-cqNDN-4jQ1KP-5sx5a9-dmFap6-91DWUb-6B76oG-arBaUB-78e93-foyuCV-7fERd4-foNKGy-6aJ39x-g8YCC9-6h7wVd-
foPab1-evFruJ-aE5gM7-6NRxcN-58rSab-j1MjXi-iaG3XX-7E3dEh-foP5VA-fB7kwF-gb1dh8-foN1oG-9ERkrW-bB7vEG-dLeT2n-9ZTHF-frgkDy-6FNiwu-
cBsgzo-db5MEV-4vBNJa-9btxNs-5C99jH-89zeHT-799RKW/lightbox/
License: CC BY 2.0 (https://creativecommons.org/licenses/by/2.0/deed.de)
• Slide 5
Dmytrok: Steam from Philippsburg nuclear power plant
URL: https://www.flickr.com/photos/klimenko/5258257970
License: CC BY-ND 2.0 (https://creativecommons.org/licenses/by-nd/2.0/deed.de)
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Pictures-2
• Slide 6
Dennis Skley: *grübel*
URL: http://www.flickr.com/photos/dskley/8627475625/sizes/z/in/photostream/
License: CC BY-ND 2.0 (http://creativecommons.org/licenses/by-nd/2.0/legalcode)
• Slide 7
Simon Adriaensen : Iconscollection - Exclamation Mark
URL: https://www.flickr.com/photos/simiezzz/1070601182/sizes/m/in/photolist-2CB7r5-7z9Uii-KY97U-6QSgJQ-Fvmus-bWyx51-22jqLK-4XsYwU-
5oZw4C-kYQHJc-f2EUTf-64E1TY-RGGyv-5KwYzN/
Licence: CC BY-ND 2.0 (https://creativecommons.org/licenses/by-nd/2.0/deed.de)
 Slide 8
Richard Matthews: Death-trap Boiler
URL: https://www.flickr.com/photos/richardofengland/6855145258/sizes/z/in/photolist-brLpRC-bFeB5o-64fvy4-4cezmH-6iD8TF-64jrC9-cp6csY-
7vgWVK-7AE8y8-csYK59-5bVLhx-ciEUz1-giZR-5RWpA9-EG6bB-PGGHC-c4Hg2C-5c14kb-5c147L-5bVLBH-64d3kv-2efZVq-Kkmfu-3gonds-8MsLab-
64a9jf-mNRPSJ-jrkahi-64FbgG-64hg1Y-64cWpn-83abcB-8A6iQ8-vtWr5-64fNBe-xA6Cf-4HgqZb-FCjds-fkxWuC-nnhLMm-4vnTTz-buDXMT-azWWjb-
64jHuG-8TfyoX-7w2jxk-6iHj2E-6dLNTN-64fSkg-64fyfK/
License: CC BY 2.0 (https://creativecommons.org/licenses/by/2.0/deed.de)
• Slide 9
Dennis Skley: Vorwärts! 240/365
URL: https://www.flickr.com/photos/dskley/9616930942/sizes/z/in/photolist-8Cbmyb-8rysKq-fDPhwb-dfkyXb-9ZfgNh-eVwGtJ-69YHXd-f4KM3C-
m1QDE-j7v6h9-evHahM-5B76pN-8Vqe6F-hWt5Vm-k61GC-6evyYv-5rivUB-eWf881-9Zfjhu-gGV4A4-79G4ie-9Zfi1E-5rnSdA-5rnSi7-6HSFQw-hBXh52-
d9mU8U-ntDGhx-foyQJV-btF3yM-nxUx3N-isa5ra-h2xviB-4oCS9i-bVMn6F-cEDi6d-bc3RMx-93CqvH-dxWQUQ-9jkUkw-gyofd9-5XhW2Q-aJJsMZ-
7xcJP9-aJ7uYn-eijZKX-9Zdysa-8iyUf8-7FQJwa-6h23S7/
License: CC BY-ND 2.0 (https://creativecommons.org/licenses/by-nd/2.0/deed.de)
• Slide 10
Kiwithing: PICTO460
URL: https://www.flickr.com/photos/kiwisaotome/13946525013/sizes/z/in/photostream/
License: CC BY-ND 2.0 (https://creativecommons.org/licenses/by-nd/2.0/deed.de)
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Pictures-3
• Slide 11
Renee Hawk: Auspuff
URL: https://www.flickr.com/photos/pictureartist/6123508940/sizes/z/in/photolist-ak7zSm-82Wxfb-4q5gMg-djAjLD-6sarLR-99DaZF-99DaiR-
99D9NH-99D9gR-99GfWU-99Gfsj-99GeJY-99D7cc-99D6GF-99Gd1w-99Gcwf-6R22fo-4cNyAt-4Tpx2v-4UABWu-5fWBTo-4UwoGi/
License: CC BY-ND 2.0 (https://creativecommons.org/licenses/by-nd/2.0/deed.de)
• Slide 12
Ramesh Rasaiyan: Water Drop!...
URL: https://www.flickr.com/photos/rameshrasaiyan/4163699892/sizes/z/in/photolist-7kW3Vb-bM3VKz-dv3BfD-mcP9vv-h72Dcf-fonceh-
fPghN8-dv9c9Y-2jW7z5-nKzJmU-mG131t-an2i2j-ei5TA3-9ovCP5-jz87Km-bpHhjs-LsUsG-3UGSzK-byY3VZ-2TCxGu-eGrDXT-x7Fh3-g6pYpv-krqDvB-
8ab4LD-99aWUm-6Rk3p4-nyMmP7-an2itJ-iUKE8K-cGAPn5-eTKTSx-an2iPw-nMYuv-dbTqkD-groL-ex2MP1-fnxqro-bYq2yN-i79kgo-8AjNDc-9XLNtv-
5wG6m1-iGqMPK-22ERid-7n7Kmi-aohzY1-gS3XAb-ebqe3A-c6XaJG/
License: CC BY-NC 2.0 (https://creativecommons.org/licenses/by-nc/2.0/deed.de)
• Slide 13
Henry Mühlpfordt: Kontrolliertes Feuer in der Nacht 2010-05-06
URL: https://www.flickr.com/photos/wimox/5208818099/sizes/z/in/photolist-8Why9B-5DALtY-9NLikq-gXQidY-ixXv3w-c7VqE1-6ZnhUq-gXReEk-
gXRd3T-gXQpC1-e3gjqb-6MjUkg-ikaM4f-bJxPLk-7PjA1r-nk5k-gXRjwz-y71a7-gXQqsL-fc2DhX-fc2BPK-fcgTaS-fc2yqp-fc2wXp-fcgLw1-9VPmF2-
9VSbdd-8Bxdaa-a96GW8-gXRg6X-a6d3qe-6kSquM-fc2sdi-hdUXSb-gXRn3g-kys92Z-gXPMLQ-bFadpe-gXQtx3-ndrba4-gXQuH9-gXPGys-jstuDc-
gXPCv6-gXPGCJ-gXPEG1-cA85w1-gXQATq-gXQENi-5XVzBz/
License: CC BY-SA 2.0 (https://creativecommons.org/licenses/by-sa/2.0/deed.de)
• Slide 14
Florian Simeth: Arbeiten von zu Hause mit dem Laptop
URL: http://www.flickr.com/photos/hangout-lifestyle/5865980513/sizes/o/in/photostream/
License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
• Slide 15, 17, 19
Bilal Kamoon: Question Mark Graffiti
URL: http://www.flickr.com/photos/bilal-kamoon/6835060992/sizes/m/in/photostream/
License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
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Pictures-4
• Slide 16, 18, 20
Photocapy: !
URL: http://www.flickr.com/photos/photocapy/3834784192/sizes/m/in/photostream/
License: CC BY-SA 2.0 (http://creativecommons.org/licenses/by-sa/2.0/legalcode)
 Slide 26
Kutchala Sutchi: Repetition, 23.03.'10, Abidjan-Yopougon (4640)
URI: http://www.flickr.com/photos/kutchala/4469943694/sizes/o/in/photostream/
License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
 Slide 27
evoo73: Windows
URL: http://www.flickr.com/photos/evoo73/3702164848/sizes/l/in/photolist-6D9yCq-68gUgN-byrkkv-6yHq7C-68qZeB-6bSytR-7MgbcK-774LZw-
65Q13g-66126u-7mwo9M-6gsSTp-64Xrqo-8UZ4bD-65WEyZ-6yDoqg-6iTjcM-6D6Bn8-6cn7SD-4YQTvN-4nXt13-59cxnL-4jJGzk-5nMcV5-5zaTqE-
5PigRp-5BzJ8t-4hyNRJ-4wSa3V-52MssZ-5ASMt2-5G4T5b-4huHLX-4ZjNaQ-4Atiro-4pV2fU-4Asw56-4x5nLb-5bVxBy-5k6PoW-5gKVHk-4og7bV-4jJHqg-
4huGaK-4YBT4N-5j5YhW-5GEMMi-5bRuuP-4hyNiE-4jNuQo-52Ducc/
License: CC BY 2.0 (http://creativecommons.org/licenses/by/2.0/legalcode)
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