LOW GRADE WHU POTENTIAL- TEXTILE SECTOR Partnership to Advance Clean Energy-Deployment (PACE-D) Technical Assistance Program R Rajmohan 12-Aug-14

CONTENTS Process Flow Sources of Low Grade Waste Heat Overall Potential WHU Solutions Case Studies

Textile Processing : Illustrative for Cotton Prints Utilities Grey Fabric Singeing Washing Mercerizing Kier Boiling Scouring/ Bleaching Dyeing Stenter Dyeing Printing Steam Aging Resin Finishing Felt Finishing Inspection Boiler Thermopac Air compressors Source: Cluster Manual Pali Textile Cluster; BEE

Textile Processing : Pali Textile cluster- Quick overview Sl No Item Target Efficiency 1 Sources of Energy Electricity from Grid & Pet Coke 2 Energy Use pattern – Pet Coke 5 to 7 TPD (Power process) 1 to 1.5 TPD (Small Units) 3 Energy Use pattern- Electricity Power Process: 3000 kWh/Day Only printing: 160-500 kWh/Day 4 Specific energy consumption ( Processing of polyester & Printing) Electricity: 1.2 kWh/Kg Thermal: 15000 Kcals/Kg Source: Cluster Manual Pali Textile Cluster; BEE

Sources of Waste Heat Drying Stente r Dyeing Jigger Singei ng Condensate Vapor Hot effluent Flue gas None Drying Stente r Dyeing Jigger Singei ng Stretc hing Water Steam (LP) 3 bar Thermic fluid 210 oC Steam (MP) 5 bar Steam (LP) LPG flame Fuel Steam (LP) 3 bar Boiler Blow Down Flue gas

Low Grade WH: Overall Potential Effluents Quantity: 3000 Kg/Cycle Temperature: 70 Deg C WHR potential: 120000 Kcals/Cycle Jiggering & Swing Steam Reject condensate: 120 Kg/Hr Temperature: 70 Deg C WHR potential: 6300 Kcals/Cycle Dyeing @ 140 Deg C Reject effluent: 5000 Kg/Hr Temperature: 100 Deg C WHR potential: 408000 Kcals/Cycle Stretching @ 120 Deg C Reject Effluent: 123 Kg/Hr Temperature: 100 Deg C WHR potential: 1230 Kcals/Cycle WHU- Overall potential 0.323 Kg of Fuel/Kg of Cloth Annual fuel savings: 93 MT/Year Cost savings: 11.2 Lac Rs/Year Drying & Jiggering Steam Reject Effluent: 200 Kg/Hr Temperature: 70 Deg C WHR potential: 12000 Kcals/Cycle Drying & Jiggering water Reject condensate: 3500 Kg/Hr Temperature: 70 Deg C WHR potential: 210000 Kcals/Cycle Mill producing 37 Kg of cloth/Hr

Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases - Economizer To Chimney Feed water Pump 200 Deg.C T1= 30 Deg.C 150 Deg.C T2 = 50 Deg.C Waste heat recovery device Usually used in boilers to recover waste heat from flue gases. Recovered heat is used to pre-heat feed water to boiler Useful where water feeding to boiler is continuous

Low Grade WHU Technologies: Waste heat recovery from Boiler/Thermopac Flue gases – Air Preheater APH FD Fan 200 Deg.C T1= 30 Deg.C 150 Deg.C T2 = 80 Deg.C Combustion air Waste heat recovery device Usually used in boilers/Furnaces to recover waste heat from flue gases. Recovered heat is used to pre-heat combustion air to boiler/Furnace Useful where Economizer exists already

Waste heat recovery device Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater (S&T heat exchanger) Boiler Flue Gas S& T H E To Chimney Water Pump Feed Water Tank Feed water Pump Waste heat recovery device Usually used in boilers to recover waste heat from flue gases. Recovered heat is used to pre-heat boiler feed water Useful when the feed water flow to the boiler is not continuous

Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater- Heat pipe heat exchanger Waste heat recovery device Usually used in boilers to recover waste heat from flue gases. Recovered heat is used to pre-heat feed water to boiler Useful to recover heat where Delta T is lower

Low Grade WHU Technologies: WHR from Boiler Blow Down – Flash Steam Recovery & Heat recovery from BD condensate Flash steam recovery from Boiler blow down Heat recovery from the condensate of the blow down Recovered heat is used to pre-heat Boiler feed water/ other hot water requirements

Low Grade WHU Technologies: Condensate Recovery Condensate recovery device No mechanical pumping Recovered condensate is used as boiler feed water Savings of both water and heat

Low Grade WHU Technologies: Heat Recovery from Hot effluents Waste heat recovery device Used to recover heat from process effluents

Low Grade WHU Technologies: Heat Recovery from Hot Vapours Hot vapors from sources like Stenters are the heat source Used to either generate hot water or to heat the fresh air to the source equipments

CASE STUDY 1 : Waste heat recovery system in Boiler

CASE STUDY 2 : Waste heat recovery system in Thermopac

CASE STUDY 3 : Waste heat recovery –Boiler Blowdown

CASE STUDY 4 : Waste heat recovery- Jet Dyeing Machine

CASE STUDY 5 : PHE – Heat Recovery from Jet Dyeing Machine (Sameer Synthetics) Temp. of water drained : 85oC Proposal : Collect hot water and use for pre-heating cold water stream used for process

CASE STUDY 2: Cost Benefit Analysis Number of Machines in Operation 9 Quantity of Water Drained/Batch/Machine 400 l Number of batches/day/machine 10 Water temperature at outlet of machine 80oC Expected temperature of effluent at outlet of PHE 38oC Expected energy savings 1,512,000 kCal/day Equivalent Fuel Savings 189 kg/day Equivalent Cost Savings 6.8Lakh Rs/year Investment 4 Lakh Rs Simple Payback Period 7 Months