1. Efficient Uses of Steam Energy in Textiles to Reduce Cost & Improve Productivity
2nd International Conference on Textile & Apparel, ICTA-2012

2. What We Do?
Forbes Marshall is an ISO 9001 company specializing in the Field of Steam Engineering & Control Instrumentation
We are working with steam for last 106 years and have our manufacturing facility in India and others in joint venture with Spirax Sarco, ARCA, Krohne, Codel & Vynce.
We manufacture Steam Boiler (NG/Diesel/Solid fuel fired), Exhaust Gas Boiler and almost all the steam system accessories.

5. Energy Audit
Forbes Marshall has an Energy Audit division having expertise in specific fields.
Forbes Marshall has conducted over 100 detailed energy audits across the industry covering each and every process including dyeing units, washing units, denim plants etc.
In each of our audits we identified the opportunity for savings ranging from 20% to 30%.
Successful implementation of our audit recommendations of these plants has yielded significant improvements in Specific Fuel Consumption (SFC).

6. Why Steam?
Fuel used for generating steam accounts for about 50% of total utility cost.
Scarcity of Natural Gas, increase in cost of fuel and hence the steam costs
Effective steam management plays a role in
Fuel Savings - which can be leveraged for cost competitiveness . Reducing fuel cost is the only route to cut costs substantially.
Product Quality – Maintaining proper steam parameters ensures product quality, e.g. uniform colour, print, brightness etc.
Productivity -Improving batch timings on equipment.

7. Benchmarking where do we stand ?
Forbes Marshall studies of over 60 textile plants reveal differences in fuel consumption within the industry.
39% difference in Specific Fuel Consumption (SFC) between the best and average plants.
The worst plant consumes more than 3 times the amount of fuel as compared to the best plant.

8. Why is the best plant the best ?
Differences in Specific Fuel Consumption (SFC) across plants on account of:
Efficient steam generation
Optimized steam distribution & utilization
Recovering condensate & flash steam
Proper steam trapping

9. Comparative Study Capacity (Kg)
Ideal Steam Consumption with Right Steam and condensate loop (Without Heat Recovery/With Heat Recovery* (Kg/Batch)
Actual Steam consumption (Kg/Batch)
Required Steam Pressure (Barg)
Actual Steam Pressure (Barg)
Batch time (mins)
Max Gradient (°C/min)
Light
Medium
Dark
250
461/281
559/379
641/461
527
660
769
3.5
6-7 5
400
660/460
711/511
770/570
782
839
890
600
863/563
1227/927
1698/1398
907
1326
1950
750
1358/758
1817/1217
1922/1322
1585
1980
2160
1500
2227/1377
2490/1640
2769/1919
2531
2982
3187

10. Not using PRV before Process machine
Common issues found because of not adopting right steam engineering practices-
Not getting right pressure & temperature in the m/c
Batch time goes high and product quality hampered
Proper steam trapping is not in practice
Running boiler at lower pressure
Not using PRV before Process machine
Not using temperature control
Many of the time traps are bypassed
Steam distribution system is not proper
Steam mains are oversized or undersized
Traps and valves leakage
Insulation of Steam & Condensate line is not proper
Not recovering condensate & flash steam
Feed water temperature is ambient
Boiler blowdown is manual

11. Valve Leakage
A 1/8 inch hole in steam main can waste 15 tons of coal or 9 tons of fuel oil per year.

12. A leaking 25 NB Thermodynamic Trap on a 7 bar line will lose steam at the rate of 18 kg/hr. This translates to a loss of more than 150 Tons of steam annually.

13. Steam is venting to the atmosphere

14. No Steam Trap / Group Trapping in Vertical Cylinder Dryer

16. Over heated + excess dried cloth
General Practice in Vertical Dryers
4 bar(g)
Over heated + excess dried cloth
Group trapping

17. Recommended Hookup – Vertical Dryers

18. Existing Hookup – Soft Flow

19. Recommended Hookup –

20. Typical Steam Circuit:
Pan
Boiler
Feed Pump
Feed Tank
Make-up Water
Vat
Condensate
Steam
Process Vessel
Space
Heating
System

21. The Steam and Condensate Loop
Distribution losses 5-7%
85%
Boiler
Process
100% Input
60% Process use
Boiler losses %
20% Condensate
So, for 1 Ton steam for process, fuel used equal to 1.67 Ton

22. Steam use in process – 60%
Different losses – 40%

23. Steam Generation
Two things are directly effect boiler steam generation –
Boiler operating pressure & Feed water temperature
Poor boiler efficiency due to-
Fluctuating loads – improper loading on the boiler which can be addressed by proper boiler selection, capacity, burner turndown, etc.
Absence of diagnostics to take corrective action – same can be addressed by steam and oil flow metering, stack monitoring with boiler load management and online efficiency check.
Manual Blow down - because of over blow down losses of money and less blow down increases the risk of boiler life.

24. Cost of a Boiler – Oil/Gas fired

25. Steam to Fuel Ratio S:F is simply a ratio of Steam and Fuel Losses
Stack
Enthalpy
Un Burnt
Draft
Steam
Flow
Fuel
Flow
Burner
Boiler
Blow down
Air
Radiation
BOILER HOUSE DIVISON

26. What affects Fuel Bill? Excess Air % Feed Water Temperature
Stack temperature
Un burnt losses
Number of On-Offs
Scaling on tubes
Soot Deposition
Blow down TDS
Moisture in Fuel

27. What to Monitor inside Boiler House ?
Steam Flow
Steam Pressure
Fuel Flow
S: F ratio
Stack Temp
% O2 in Flue gas
Feed Water Temp
Blow down TDS
Furnace Pressure

28. Factuals
Deviation in 2% oxygen Results in 1.5 % Excess Fuel Consumption
10 % Excess Blowdown will amount to 2 % Excess Fuel Consumption

29. Boiler Efficiency Monitoring System

30. 100 - { } Boiler Efficiency + + + = Losses In Direct Efficiency Draft
Stack
Enthalpy
Un Burnt
In Direct
Efficiency
100 - {
Draft }
Steam
Flow = +
Fuel
Flow
Burner
Boiler +
Blow down +
Air
Radiation

31. Conclusion
Fuel
Scope for savings (%)
Gas
11.2 %
Liquid
11.8 %
Solid
17.1 %
No Matter which fuel type you look at, the scope of savings is 10 % to 15 % at least.
No boiler is an exception

32. Steam Distribution
High distribution loss across plants on account of -
Improper line sizing
Improper insulation
Improper line routing & condensate removal from steam lines
These losses can be addressed by -
Proper design of the distribution network, i.e.; proper line sizing without extra provisions for expansions
Proper insulation and efficiency checking mechanism
Proper condensate removal from steam lines
Diagnostics – pressure and temperature gauges, steam flow meters, etc.

33. Distribute Steam at High Pressure
This will have the following advantages:
Smaller bore steam pipes needed and therefore less heat (energy) loss due to the smaller surface area.
Lower capital cost of steam mains, both materials such as pipes, flanges and support work and labour.
Lower capital cost of insulation (lagging).
The boiler can be operated at the higher pressure corresponding to its optimum operating condition, thereby operating more efficiently.
The thermal storage capacity of the boiler is increased, helping it to cope more efficiently with fluctuating loads, and a reduced risk of priming and carryover

34. Pipe Sizing Greater Cost Greater Heat Loss
Greater Volume of Condensate Formed
Lower Pressure to Steam Users
Not Enough Volume of Steam
Water Hammer and Erosion

35. Slug of water from condensate
Waterhammer
Sagging Main
Condensate
Slug of water from condensate
Vibration and noise caused by waterhammer

36. Relaying to Higher Level
Fall 1/250
Steam
Relay
to high
level m
Drain Points
Steam Flow Flow

37. Proper Condensate Drain
Steam Flow
Condensate
Cross Section
Correct
Incorrect
Pocket
Steam Trap Set
25/30m
Steam Flow
Cross Section
Steam Trap Set

38. Branch Connections
Steam
Steam
Condensate
ûIncorrect
üCorrect

39. Drainage of Condensate from Steam Line
Steam Flow
Separator

40. Importance of Moisture Separator
Fig. Temperature profile across a heat exchange surface

41. Steam Utilization Steam Trapping -
In most plants, trap selection is an issue on heating applications.
Group trapping on equipment also needs to be addressed.
Across textile plant audits and surveys we have conducted we find that only 50% of the installed traps are OK.

42. TD Traps are used in Process, it should be float trap
Disadvantages of TD:
-Intermittent discharge.
-Condensates not removed properly, get water logged.
Increase steam consumption by 8~10%
Increase process time
By 25~30%

43. Ball Float Trap: Ensures proper removal of condensate from the process as soon as it forms. Recommended for process application.

44. Condensate & Flash Steam Recovery
Huge gap between quantum of condensate being recovered and potential for recovery observed across all plants.
Across many plants, boiler feed water temperature is ambient and condensate is being drained.
In plants where condensate is recovered, it is doing using an electrical pump leading to loss of useful heat.
Flash steam is normally not recovered and is vented. Flash steam can be recovered and used for feed water heating.

45. This calculation is made for diesel fired boiler
* This calculation is made for diesel fired boiler Similarly it can be done for gas fired boiler.

46. Multiple Benefits of Condensate Recovery
Condensate water contains 20% energy of steam. Returning condensate improves the feed water temperature and thus lowers fuel bill.
Returning condensate to feed water tank cuts the makeup water requirements.
The condensate returned does not need to undergo water treatment and thus saving treatment cost.
It has no TDS. It reduces the requirement of blowdown thereby curtailing blowdown losses.
Reduce the cost for oxygen scavenging chemicals, since the improved temperature will reduce the amount of dissolve oxygen almost 75%.

47. Multiple Benefits of Condensate Recovery
Higher feed water temperature by recovering condensate increases the boiler output with reduced fuel consumption.
Recovering flash steam is as important as recovering condensate water. Flash steam contains 50% energy of the total recovered condensate, although it may be 10~15% in mass.
[Please Note: Holding condensate in collection tanks reduces the condensate temperature via radiation losses. Condensate should be returned as soon as it formed. ]
Every 60C rise in the feed water temperature by using condensate water & flash steam gives 1% saving in fuel.

48. Benefits of Condensate Recovery:

50. Energy Content in Dye Liquor
Not considering losses the Process Heat Recovery in Dyeing m/c
45 %
15 %
Dye Bath Liquor
Cooling Water
Energy Content

51. Benefits of Dye Liquor Heat Recovery
Recover heat from dye liquor 60~80 deg C from the dyeing machine. Savings up to 15% in steam used for hot water preparation.
Pre-heats process water to the dyeing machine. 1-2 extra batches per week possible.
Facilities low temperature discharge to ETP. Helpful for effluent treatment.
Eliminates pressure fluctuation of boiler.

52. Dye Liquor Heat Recovery System

53. Enconomy opportunities
Trap Management
Selection of right Trap
Bypass
Leakage
Stop Leakages
Insulation
Condensate Recovery
Flash Steam Recovery
Stop Blowdown Losses
Feedwater tank Management
Stop Waste (12-15%)

54. Encon opportunities Steam Flowmetering Dye Liquore Heat Recovery
Efficiency Optimisation
Liquor ratio control
Steam Pressure Control
Temperature Control
Instant Hot water supply
Dryness of Steam
Capacity Utilisation
Optimization ( 8-10%)
Waste Management

55. Encon Opportunities Boiler Efficiency Monitoring
Waste Heat Recovery Boiler from Generator
Thermic Fluid Generator-Efficiency % optimisation
Hot water from DG set Jacket
Optimization
Waste Management
Heat Recovery (7-8%)

56. Our recommendations which included –
Optimized steam generation
Improved steam distribution system
Proper selection and sizing of steam traps
Better management of the process like installing temprature & pressure controls
Utilizing waste heat recovery
Recovering condensate with flash steam to improve the boiler performance

57. Forbes Marshall has a Consultancy Division worked for the project design and consultancy for steam, water & air distribution system to make the industry energy efficient and sustainable. Forbes Marshall has done Consultancy in many industries of Bangladesh. Few of them are, Hameem Denim, DBL, Ecotex, GMS composite, Graphics Textils, etc.
Copyright Forbes Marshall,

58. One of Many Successes in Bangladesh!!
Industry Knit Concern
Location Narayangong
Steam Usage Fabric Dyeing, Finishing & Garments
Fuel Gas
Cutting
Costs
Down
Before Energy Audit -
They have a requirement of 3~4 TPH boiler
Their machine was starving for steam
After Energy Audit & Implementing Recommendations –
Till now they have no shortage of steam and no requirement of steam boiler
Reason found :
Wastage and leakage of steam in different points
Condensate was not recovered
Boiler was running under pressure
Too much blowdown losses
Live steam wastages from garments section.
Copyright Forbes Marshall,

59. 0.28 Kg Wood/ Mt Cloth (Rs0.58/MtCloth)!!
One of Many Successes!
Industry Textile Processing Unit
Location Madhya Pradesh
Steam Usage In Process eqpt – Stenters, Back filling M/cs, Calendar M/c etc
Fuel Wood
Cutting
Costs
Down
The objective - Improve SPFC from 0.33 kgs wood/mt cloth (Rs 0.66/ mt cloth).
Energy conservation recommendations implemented by customer
optimized fuel management – sizing.
Optimized steam generation
undertook better management of process like temp control.
optimized waste heat recovery
reduced losses on account of inappropriate / in-operational trapping
The Results?
The SPFC came down to
0.28 Kg Wood/ Mt Cloth (Rs0.58/MtCloth)!!
Copyright Forbes Marshall,

60. Customer Saves Rs 30 Lakhs/year!!
One of Many Successes!
Industry Textile Processing Unit
Location Gujarat
Steam Usage Yarn Dyeing M/cs
Fuel HSD
Cutting
Costs
Down
The objective – Reduce Fuel Consumption
Energy conservation recommendations implemented by customer
Optimized steam generation
Reduced losses in steam distribution circuit
undertook better management of process like temp control.
optimized waste heat recovery – dye liquor, condensate & flash recovery.
reduced losses on account of inappropriate / in-operational trapping
The Results?
Before
After Audit
Fuel Consumption (lts/day)
1,150
820
Costs (Rs/day)
17,250
9,020
Customer Saves Rs 30 Lakhs/year!!

61. One of Many Successes!
Cutting
Costs
Down

62. One of Many Successes!
Cutting
Costs
Down

63. Find out where you stand!!!
Fuel prices would continue to spiral upwards……. & so would your losses!
The longer you wait…..
The more your losses accumulate!
Find out where you stand!!!
Get a free scoping study done by FM Experts

66. Bangladesh Office Address:
3rd Floor, Rupsha Tower, Kamal Ataturk Avenue,
Road -17, Banani C/A, Dhaka.
Website:

67. Thank You