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

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Presentation on theme: "LOW GRADE WHU POTENTIAL- TEXTILE SECTOR 12-Aug-14R Rajmohan (PACE-D) Partnership to Advance Clean Energy-Deployment (PACE-D) Technical Assistance Program."— Presentation transcript:

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

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

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

4 Textile Processing : Pali Textile cluster- Quick overview Source: Cluster Manual Pali Textile Cluster; BEE Sl NoItemTarget Efficiency 1Sources of EnergyElectricity from Grid & Pet Coke 2Energy Use pattern – Pet Coke 5 to 7 TPD (Power process) 1 to 1.5 TPD (Small Units) 3Energy Use pattern- Electricity Power Process: 3000 kWh/Day Only printing: kWh/Day 4Specific energy consumption ( Processing of polyester & Printing) Electricity: 1.2 kWh/Kg Thermal: Kcals/Kg

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

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

7 Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases - Economizer 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 Boiler Flue Gas ECOECO To Chimney Feed water Pump 200 Deg.C T1= 30 Deg.C 150 Deg.C T2 = 50 Deg.C

8 Low Grade WHU Technologies: Waste heat recovery from Boiler/Thermopac Flue gases – Air Preheater Boiler/ Thermo pac Flue Gas APHAPH 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

9 Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater (S&T heat exchanger) 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 Boiler Flue Gas S& T H E To Chimney Water Pump Feed Water Tank Feed water Pump

10 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

11 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

12 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

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

14 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

15 CASE STUDY 1 : Waste heat recovery system in Boiler

16 CASE STUDY 2 : Waste heat recovery system in Thermopac

17 CASE STUDY 3 : Waste heat recovery –Boiler Blowdown

18 CASE STUDY 4 : Waste heat recovery- Jet Dyeing Machine

19 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

20 CASE STUDY 2: Cost Benefit Analysis Number of Machines in Operation9 Quantity of Water Drained/Batch/Machine400 l Number of batches/day/machine10 Water temperature at outlet of machine80 o C Expected temperature of effluent at outlet of PHE38 o C Expected energy savings1,512,000 kCal/day Equivalent Fuel Savings189 kg/day Equivalent Cost Savings6.8Lakh Rs/year Investment4 Lakh Rs Simple Payback Period7 Months


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