1. Energy Conservation Potential of Measurement & Control Systems and Energy-Saving Equipment In Textile (Dyeing) Processes by: Dr. Attia Saad El-Din Energy Conservation Potential of Measurement & Control Systems and Energy-Saving Equipment In Textile (Dyeing) Processes by: Dr. Attia Saad El-Din TIMS - Egypt Energy Conservation Center, Japan & TIMS March 2000 Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

2. Introduction In the textile industry, one of Egypt's major industries, most of the equipment and machinery appears to be outdated, and measuring equipment is not sufficiently available. Hence, taking appropriate measures will lead to a substantial saving in energy. In this context, a quantification of the energy conservation potential of Egypt's textile (dyeing) industry, the effect on greenhouse gas reduction and the effect of investment for these purposes is expected to lead to the identification of great opportunities that would contribute to achieving CDM goals as well as to Egypt's national interest. Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

3. Schematic Diagram of Technologies Covered by the Project Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

4. Equipment Covered by the Survey Dyeing process Jet dyeing machines, winch dyeing machines, mercerization dyeing machines, etc. Drying process Stenters, suction drum dryers, etc. Utility facilities (heat sources for the dyeing and drying processes) Steam boilers, thermal oil boilers, and the piping for such boilers Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

5. Project Examined Technologies The following 5 items constitute the technical basis for energy conservation effect. 1. Heat insulation of machine proper and steam piping 2. Enhancement of measurement and control 2.a Dyeing process: Attainment of optimum dyeing conditions 2.a Dyeing process: Attainment of optimum dyeing conditions 2.b Drying process: Achievements of optimum drying 2.b Drying process: Achievements of optimum drying conditions conditions 2.c Finishing 2.c Finishing 3. Recovery of cooling water and heat recovery from hot/waste water water 4. Recovery of condensate 5. Introduction of energy management system 5.a Optimization of boiler air/fuel ratio and operating pressure 5.a Optimization of boiler air/fuel ratio and operating pressure 5.b Centralized energy management system of utilities 5.b Centralized energy management system of utilities (energy fuel, steam, electricity, water, … etc) (energy fuel, steam, electricity, water, … etc) Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

6. Current State of Subject Equipment by Factory Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

7. Base Line for Energy Consumption Type of Equipment by Factory (Zenotex) Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

8. Base Lines of Energy Consumption for 11 Factories Surveyed Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

9. Specific Energy Saving by Energy Conservation Measures Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

10. Specific Energy Savings by Factory Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

11. Base Line for Emission Volume of Greenhouse Gases for Each Factory t Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

12. Specific Reduction in Greenhouse Gas Emission for Each Factory Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

13. Summary of CO 2 Reduction and Energy Conservation Potential for 11 factory surveyed Energy Savings CO 2 Reduction Calculation results Items Items 14,449 toe/year Energy reduction Volume 44,702 tons/year CO 2 reduction volume 22.4 Energy reduction rate 22.4 CO 2 reduction rate 838.56 million yen Investment cost 838.56 million yen Investment cost 17.2 toe Energy reduction/ million yen 53.3 tons CO 2 reduction/ million yen 5,800 yen Investment cost per unit of energy (toe) 18,750 yen Investment amount per ton of CO 2 Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

14. Effect on Productivity The promotion of energy conservation through measurement and control recommended in this survey leads to the improvement of productivity. Because optimum energy control in the manufacturing processes allows automatic control of operation at the temperature, humidity, etc., most appropriate for production, the defective product rate declines significantly (yield improves) as compared with manual control. Moreover, improvement of product quality can be expected. At present, Egypt's textile products are losing international price competitiveness with Southeast Asian products, and in this context, it is increasingly important to strengthen international competitiveness through higher quality and reduced prices, thereby promoting exports. While the improvement of quality, as well as that of productivity, is necessary, this project is designed to attain these two purposes concurrently, and it is thus considered to comply with the request of the Egyptian side. Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX

15. Effect on the Egyptian textile (Dyeing) Industry Reduction of approximately 22.4% (160,000 toe/y) of the total energy consumption. Base line for this estimate: 1.Energy consumption by the textile sector: 1,433,000 toe/year 2.Energy consumption by the dyeing industry: 717,000 toe (50% of the total energy consumption). 3.Probable approaches to dissemination of the effect of this project include: 1.Financial assistance (Yen loans, "Carbon Fund" including WB and EPP Fund, 2.Technical assistance, 3.Development of human resources (training) Baseline Cairo, March 31 & April 1, 2004 TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX