FUNDED BY THE EUROPEAN COMMISSION S ustainable and C leaner Production in the Manufacturing I ndustries of Pak istan SCI-Pak Mar Feb 2012

 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

Fuel (Natural Gas) Electricity Water Steam

More than 30% Reduction in Energy bills 70% 30%

Reuse of cooling water (compressor, pumps, therm oil heaters, chillers, singeing, jets, kiers) (Savings-Rs. 50, ,000/year) Payback 6 to 12 months

Minimize by increasing temperature

Fixed O2 Analyzer Portable Stack gas Analyzers Savings 5-10% boiler fuel savings (1% excess oxygen reduction in stack gas saves approximately 1% fuel)

1 ft 2 heating surface area = 3 kg steam/hr

Savings-Rs. 100,000/year-leak control Payback 2 months

Savings-Rs. 4,000-5,000/year-m Payback 6 months

RO plant for water treatment Water Softening Plant 1 mm thick scale in boiler increases 3 % fuel consumption

Recovery of heat from hot wastewater (Savings-Rs. 900,000-1,000,000/year) payback 6 months (Also De-scale properly)

Recovery of heat from exhaust gases of steam boiler, therm oil heaters, generators (Savings-Rs. 1,800,000-2,000,000/year) Payback 6 months

Every 22 °C reduction in stack gases will increase efficiency of heater by 1% Install Economizer to recover heat from thermal heater stack gases

Pay Back Less than one year

Pay back 6-8 months

Pay Back 7-10 months

 Type, alignment, placement  Investment  Nominal for repairing  Rs. 5,000-20,000 for trap replacement  Savings  40,000-50,000 per year per steam trap  Pay back 3 months

Characteristics (FT, IB, TD) Condensate dischargeContinuous Intermittent Energy conservationExcellent Poor Corrosion resistantExcellent Resistance to wearsExcellent Poor Ability to vent airExcellentPoor Handling of startup air loadExcellentFairPoor Operation against back pressureExcellent Poor Performance against light loadExcellent Poor Response to slug of condensateImmediate Delayed Ability to purge systemFairExcellent Failure conditionCloseOpen Dirt handlingPoorExcellentPoor Handling to flash steamPoorFairPoor Resistance to hydraulic shocksPoorExcellent Resistance to freezing damage PoorGood Comparative Physical SizeLarge Small

Pay Back within one year

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

Reuse of steam condensate as boiler feed water (Savings-Rs. 500, ,000/year) Payback 8 months

Replace T12(40W) Tube Lights with T8(36W) (electronic Chock) Pay Back 5 ~6 Months

 Replace Class III Motors with Class I Motors Payback is 1 ~2 years

Leakage monitoring and control  Immediate Pay back Pressure Optimization Variable Speed Drive (VSD)  Pay back 1 year Use cool dry air at suction o 5 o C reduction in suction air temp-1% reduction in power Replacement of piston compressor with screw compressor Small diameter hose for cleaning