Energy Conservation in Textile Industry Ashokkumar

Research Article Volume 10 Issue No.7

Energy Conservation in Textile Industry Ashokkumar. A1, Gowthaman. P2, Gowtham. K3 Assistant Professor1, Student2, 3 Department of Textile Technology Bannari Amman Institute of Technology, Sathyamangalam, Erode, India

Abstract: In textile mill, electricity consumption is in increasing trend, due to modernized machines and continuous usage of the equipment’s in inefficient operating parameters. Textile sector may be considered as one of the largest industrial sector in India and at the same time it is also one of the oldest sectors in the country. Even after a lot of technological development globally, most of the mills are using the same old technology. The energy cost is around 15% - 20% over the production cost and it stands next to raw material cost. Hence now a day’s area of focus is towards energy consumption at load end and by optimizing the efficiency of the motor. Although for the last few years process of modernization in textile industries are underway but still the pace is slow. So, in order to include major players of textile sector as well as other energy intensive industries for energy efficiency movement. In this paper, influence of various areas of energy consumption and process of optimization in textile mill on energy conservation is discussed with practicaldata.

Key Words: Electricity, trends, production cost, raw material, energy conservation.

1. INTRODUCTION: energy in many areas like spinning, weaving and garment also when the electric consumption and the power cost is will be Textile Industry in India is one of the vital components of the increasing trend due to the moderation of the machine and also Indian economy and contributing around 14%. of total industry the continuous usage of the machine is an ineffective operating production, about 4% of India’s Gross Domestic Product (GDP), parameter the power cost and the man power cost also shortage about 17% of the gross export earnings and employing about 35 by the textile industry so that the electricity cost are always million people being the second largest provider of employment higher due to the dusty of an environment and the heavy noise after agriculture. Taking the installed capacity of spinning will be produce by the inside of the mills. In the spinning machinery only, it ranks second (with 19.6% of total spindles industry there are so many energy is needed like the blow room globally), after China. In textile industry, electricity the bale will be open by help of mechanisum so we need energy consumption and power cost is in increasing trend due to from the outsource like electricity in energy conservation and modernised machines and continuous usage of the machines in the more no of air pressure also needed for producing the yarn so inefficient operating parameters Apart from the power cost, man that type of process we need more power consumption in power is also shortage in textile mills due to dusty environment spinning industry and also the humidification plant is one of the inside the mill and heavy noise from the textile machines. Due important for the spinning industry we need to control the inside to these reasons workers are not showing interest in working at humidity by the help of air. In one kilogram of yarn will textile mills, which compel mill management to deploy more produce by the help of 8.45 unit power will be needed so the automated machines. Hence, textile machinery manufacturers energy conservation is most important in the textile industry. are integrating automation in the machines, indirectly From the above graph the major power saving from the requirement of power of the machines is increased. The main preparation of the preparatory process, ring frame, objective of the textile mill is to produce yarn (thread) from the humidification plant and the air compressor. Apart from this raw cotton which requires six stages of process. These are there may be a chance for losing the power in to the cable loss. discussed briefly for readers understanding. The implementation Cable loss and power factor are play with the major roll for the of energy conservation programmes in spinning mills has gained textile industry to conserve the energy. The power factor will be wide acceptance in the back-ground of the rising cost of energy. varying from 0.8 to 0.96 at the load of the machine the voltage With more and more utilisation of electrical energy and faster fluctuates from 395VAC to 430VAC load at the side of the growth of industry, the impetus on energy conservation is machines the actual yarn production has been collected from the increasing by leaps and bounds. The pressure of energy bill and mills at completed year in month- wise. The 1kg of yarn need at pressure on the total available energy is very much needed for average at 8.45 units of electricity during the year at 2010. further development. The most important thing is conversion of electrical energy into mechanical energy. Normally the 3. ENERGY USE IN THE TEXTILEINDUSTRY: conversion efficiency is 85%. But even 1% increase in this figure will reduce theenergy. In textile industry there will be comprises a large number of plant which will be consume and significant the amount of 2. ENERGY DISTRIBUTION IN TEXTILEMILL: energy the total manufacturing will be consumed by the textile industry which will depends on the structure of the IN the textile industry there are many areas were used in the manufacturing sector in our country for instant the textile

IJESC, July 2020 26791 http:// ijesc.org/ industry accounts from the 4% of final energy consumption that and the machine parameters also which gave good energy saving will be manufacture by the china while share the less than the2% in ring frame it optimization of the speed can be set with the of energy in U.S. The total product cost expended on the energy respective length of the yarn produce at the ring spinning . By in textile industry also varies by country. In general of cost setting speed of the curve wave at maximum speed will be factors for 20TEX combed cotton yarn in several country the reached we get the 25% of the final length yarn to be produce. energy cost will be offended by three and four highest share of This method which helps easy way of no speculation power the total product cost. The large quantities of the both electricity saving. For every ring frame and speed frame machines where and fuels to share the electricity fuels with the total final uses in over head travel cleaning device(OHTC) can installed in blow the textile industry by the ring spun yarn electricity in dominant and sucking the dust in pipe way and travel one end to another energy resource whereas the we-process in the major energy end on the machine the continuous running of OHTC at one end resource by the manufacture cost by increased in 2003 will be to the other end at the reversing side of the machine will be upgrade up to 18-20%. stopped for 1 min to 5 mins they give good energy saving without any investment. 4. ENERGY SAVING IN BLOWROOMDEPARTMENT: 6. ENERGY SAVING IN HUMIDIFICATIONPLATS: In the blowroom department where mixing the material from the bale opener and the mixing of material in different fibre like Mills humidification plant which play as a vital role for RH cotton and polyester by removal of cotton seeds and the small relative humidity at the temperature by the yarn process the tufts and cleaning from the external impurities the cleaning is number of motors are employed at the towering by the energy achieved by the combination of resolving the beaters where saving zones the individual motor has been study at positioned by the vertical and horizontal grid bars are the humidification plant the motor load will be gather than the rated suitable arranged the material where once the arrangement by power and also the power factor will be individual motor looks the machine conveyed to the next machine by the air suction by the performance of the humidification plant. In the mill were create the removal of waste generation will run depending upon four plant for main relative humidity in spinning mills the power the production required and how much material we can feed the study has been study at the separate motor for that four plants. induction motor employed by the elimination for raw cotton The load pattern of the motor which consider by 92% at impurities out of the 15 to 54 motors are employed while maximum by during the power study the load percent of the underutilized by conducting of power analyse the selective motor had been increased at92% the power study will be taken motor are changing the appropriate motor power with the for complete all mills plant. respective load and also conducting the power of connection will varying from the delta to star. The motor running speed will be 7. ENERGY SAVING INCOMPRESSOR: taken by the working hours in 24h in the plant as the result a unit The power study of this compressors can be conducted by the will be saved per hour in 2.15KWh so that the unit is 5.16 units before tuning of ON and OFF time of compressor while conduct per day for producing the removal of seeds and the impurities in the power study on cooling motor by over load by 1.36 KW at the blowroom lines. In per month we save the 1548 units per the maximum load at 92% of power savings. The compressor moths would be save by the above technique. blowroom will be will give the air at the rotating speed so that the air will passing running at the continuously irrespective to the material we through the help of pipe lines at different section in different required in cotton material for subsequent with the other flow rate by help of air pressure meter if it any loss at the pipe machine like carding the ratio of the blowroom will be tuned at line so the power consumption is high so we should monitor at 95:5 ratio by save the energy by 37.46KWh per day in power the each hours. audit thereis no improving the opening and cleaning efficiency by the blowroom machine but it save the energy so the 1123.9 8. ENERGY EFFICIENCY IN IMPROMENT OPPORTUNITIES IN KWh energy will save per month. In the blowroom line to TEXTILE INDUSTRY: collected the wastes from the machine and the several machine will be installed. The waste collected system consist of three fan It means the both opportunities from the process will be motors connected with the pipeline by individual machine optimized and well complete replacement of the current according to the air suction required. By the reducing the machinery with state of the art as new technology they specially pressure at 1000 pa to 700 pa waste collection system so the attached and paid retrofit measure of the art technology has been energy has been saved at102 KWh perday. high often capital cost so that the energy will be saved by the result of replacement with the current equipment at the new one 5. ENERGY SAVING IN RING SPINNINGMACHINE: and high cost but the safety is more power consumption less so the benefit is installed in new technology such as saving the The ring spinning region is will be contributed around the 50% water, material savings wastage also very less, waste water is total power installed the combination of speed frame and the also less, don’t do again and again in the same mistake and high ring frame also called as the ring spinning region and we reduce production quality so that the new technology are more the thickness of the sliver and twist manipulate which will economically. required for weaving process during the power they will be concentrated the ring frame which conserve the energy in mills 9. BREAK DOWN OF ENERGYUSES: the absorbance of the ring frame machine where running as the lesser efficiency at 91.5% on the main motor where we replace The break down means the significant losses of energy with the the higher efficiency of motor at 94.5% in one machine at the textile plant so that the onsite energy loss are around in 36% of trail basis at the study has been conducted with the same process energy input in U.S textile the motor driven system have the

IJESC, July 2020 26792 http:// ijesc.org/ higher energy waste at the percent of energy waste at 13% from 10.2.IMPROVING THE EFFICIENCY OF FUELUSE: the following distribution at the 4 boiler loss at 7% to 8% of the By selection of fuels with the good fuel gas had been loss is required by the varies textile industry in the other country chacteristics by adding the high calorific value and the ease as shows that the motor working waste generation at U.S textile combination are desired at the air pollutions can provide that industry. much as possible the selection of boiler are used in textile industry has been expire by the replacement of Lancastrian or 10. ENERGY CONSERVE MANAGEMENT INTEXTILES: else scotch type tuber are used and smoke tube to water tube boiler are efficiency toimproved. The energy management while relative to the wide range of textile department it is necessary to enhance the awareness to 10.3. IMPROVING EFFICIENCY USE INSTEAM: improving the knowledge to the participant and the cooperation Piping is the amount of steam in textile industry involved is not to the every person which involving the production process. a so large where steam are required are wide space from the steam loss due to heat radiation from the transport pressure drop 10.1. IMPROVING EFFICIENCY INELECTRICITY: are considerable the steam are transport at the over long distance Lighting is the nature of operations by sharing the light using the at high pressure and small diameter rather than the low power electricity is high to glow there is an important to the re- ids required in a large diameter. Steam accumulator can be examination of the light source by utilizing the most efficiency installed in midway through the heat transport to pipe in of electricity savings. Then the electric motor we use more between the boiler heat consume load in the order to store steam energy in motors and also the more small motors are used in in load the light while heat transforming it to the heated water. textile industry like conveyer and the transporting in one side to another side at bales and slivers also so the conventional 10.4. UTLIZATION OF HEATEXCHANGER: machine was driving the single motor with generate the In each production process the textile industry, heating and mechanical energy to transmit the various part of the textile cooling of a gas liquid are medium heat at frequently that can be machine at the collective manner in many off the industry they exchanges between a different flow of fluids and order to avoid using in mordon machine that will utilized by the more multiple contamination or else the chemical reaction at the direct contact power with compare to the old machine and they will utilized by heat are carried out by the indirect heat are cooling. the multiple control boards by controlling in a each moment of the motor which is directly coupled to the machine part to drive 10.5. ENERGYAUDIT: independent to other motor. The final one is electricity heating Energy audit means the survey inspection to analysis the energy in textile industry heat has play the largest roll with replace to flow from the energy conservation in an textile industry to the other methods likewise STEEM, GAS HEATING AND reduce the amount of energy into the system output without the DIRECT OR INDIRECT HEAT from the order of achieving negatively at affected the output. The light spark contactor the cost. So the electricity saving is the most important for switches and also the loss joints and also the heating in motor textile industry if it is not controllable it will be difficult to run load and other load are coupled to the friction, metal to metal the industry. touch, poor lubrication and misalignment.

11. RESULT ANDDISCUSSION:

Table.1. Power distrubution in textile industry by including production and non production lines: DESCRIPTION INSTALLED, KW TOTAL LOAD, % Blowroom 58.78 2.39 Carding 327.6 13.32 Drawframe 61 2.48 Comber 59.23 2.41 Speed frame 68.32 2.78 Ring frame 1,158.88 47.12 Autoconer 196.35 7.98 Winder 26.4 1.07 Humidification plant 284.3 11.56 Waste collection 45.48 1.85 Buffing 7 0.28 Compressor 93 3.78 Lighting 35.15 1.43 Seawage plant 7.25 0.29 Water pump–hostel 18.7 0.76 Admin office, QC, hostel 11.84 0.48

IJESC, July 2020 26793 http:// ijesc.org/ Table.2. unit saving after changing the new motor in mordon spinning industry: NAME OF THE ACTUAL PERCENTAGE OF POWER—AFTER POWER MOTOR POWER, KW LOAD IMPLEMENTATION KW SAVING, KWH/H Material feed 2.5 33.33 1.5 1 motor Ventilator motor 5.5 137.5 NA 0.55 Condensormotor 3.2 58.18 2.6 0.6

Table.3. Power saved after the mode changing in ohtc in ringframe: PARAMETERS NORMAL MODE POWER SAVING MODE HS end stop time 5 123 TS end stop time 5 123 Run time 2 min 23 s 2 min 23 s Units consumed/h, kWh 2.068 1.276 Units saved/hour/machine 0.792 0 Total run h/day, h 18 0

Table.4. actual power consumption of humidification plant in ringspinning system in auto coner: Name of the motor Name plate details Actual power consumption Load, Difference, kW % kW I V I P.F kW Pneumafil exhaust 9.3 398 11.4 0.66 5.1 55.3 motor (Spg)

Exhaust motor (Spg) 7.5 14.8 381 13.3 0.81 7.1 94.4 0.18

Supply fan-1 (Spg) 7.5 14.8 389 7.66 0.98 5.2 69.3

Supply fan-2 (Spg) 7.5 14.8 394 6.9 0.97 4.5 60.3

Table.5. Total power saving in over all spinning lines: LOCATION KWH SAVED/MONTH Preparatory—motor 1,548 Preparatory—process 1,123 Preparatory—waste collection 3,060 Ringframe—motor 1,122 Ringframe–speed 7,260 Ringframe–OHTC 9,390 Ringframe–fan motor 13,440 Humidification plant 10,230

LOCATION KWH SAVED/MONTH Compressor 4,560 Total units saved 51,733

12. CONCLUSION: cost-effective options often are not implemented in textile plants due mainly to limited information on how to implement energy- Energy is one of the main cost factors in the textile industry. efficiency measures, especially given the fact that the majority Especially in times of high energy price volatility, improving of textile plants. Hence, by incorporating the above technique in energy efficiency should be one of the main concerns of textile all the textile mills, ample energy can be saved. In general, most plants. There are various energy-efficiency opportunities in of the mills have not included renewable energy techniques in textile plants, many of which are cost-effective. However, even productive and non-productive machines. By means of adopting

IJESC, July 2020 26794 http:// ijesc.org/ these techniques, significant energy saving can be realised.

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