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The Textile Industry in India is one of the largest process industry (and one of the oldest) in terms of number of
plants.
With an increase in competition and the removal of quota system, most of the Textile process houses were
forced to look at cost reduction to survive.
The priorities for cost reduction were originally determined in the early/middle ‘90s based on the proportion of
cost attributed to different components like raw material, utilities, man power, financial costs etc. At that point
of time the priority was reduction in raw material costs as it contributed almost 50% in the total cost. Next in
priority was the combined utility – i.e. electricity, fuel for steam / thermic fluid, water and compressed air.
Within the utilities the focus was much more on electricity to begin with – as the cost of electricity was
increasing and the availability was unreliable.
This focus in late ‘90s yielded a very good result coupled with opportunity provided by opening of markets and
availability of raw materials (dyes, chemicals etc.) at very low rates (especially from China).
Cost of fuel for generating Steam / Thermic fluid in the meantime continued to grow steeply, nearly offsetting
the benefits of reductions achieved in other areas. This brought focus to this utility and brought in the limelight
the limited knowledge and bench marks available for the industry to take concrete actions to curtail the growing
costs.
Forbes Marshall, a pioneer in the field of Steam Energy Conservation, has worked with the textile industry over
the last 60 years especially in India, Srilanka and Bangladesh, apart from other countries. Along with
Confederation of Indian Industry, Forbes Marshall initiated a bench marking exercise for specific fuel
consumption in Textile Industry.
The findings are elaborated herewith, to have uniformity of data and draw representative conclusions. We are
presenting here case studies in India with similar plants, processes and end products
Tirupur Region
Bhilwara Region
Looking at the data available above and the work we at Forbes Marshall, have done with Textile Industry in the
last 60 years, we are briefly putting down opportunities for energy savings – with influencing factors / causes
and remedies in the design of utility or operation of the process.
We are classifying the entire steam and condensate loop into 3 segments.
Steam Generation & Distribution
Steam Utilization – based on the type of process
Condensate and flash steam recovery.
Process’s in Textile Industry can be segregated into following segments & opportunities identified separately
for each –
Batch wet processing under pressure
Batch wet processing – Atmospheric
Continuous Processing
Main opportunity for Energy Savings in Batch Wet processing under pressure –
Sr. Area Actions
No.
1. Reduction in liquor ratio - Based on process requirement
- Operating practices – how precisely are the ratios
controlled practically; are proper measurements in place?
2. Reduce & maintain process - Properly sized & selected temperature controls
time
3. Reduce batch / process time - Proper condensate removal from HEX area
For continuous processing, the areas are similar with further focus on flow characteristics, counter flow
operation, improved washing action, automation of process etc.
Other process’s like drying cylinders etc. the issues related to energy conservation revolves around proper
conditioning of steam and condensate removal from heat exchange areas –
a) Reduce steam pressure
b) Removal of air for steam systems
c) Proper steam trapping
d) Proper selection & maintenance of rotary joints & syphons.
Condensate heat in most energy conscious plants is being recovered back to boiler feed tank or for use in the
process.
However, a major opportunity exists in recovering the flash steam heat which is universally wasted. Systems
designed to recompress the atmospheric or low pressure flash steam to a reusable pressure can be designed
specifically for this purpose.
Overall the opportunity to conserve energy in steam systems in Textile Industry is tremendous, however to
avail of the benefits we need to be specific with data such as operating hours, parameters, benchmarks etc.
For all of above to happen, the starting point is to have a diagnostics and monitoring mechanism in place for all
key parameters.
Also simultaneously a well designed and installed steam system may not yield adequate results unless proper
operating practices including enhancing the Energy Awareness at all levels in the organization is systematically
implemented.
A Case Study on Specific Fuel Consumption Approach for Value Addition;
Terry Towel Plant in Western India
Forbes Marshall did an Energy Audit at a Terry Towel plant in western India. The plant was
manufacturing of Towels with a capacity of 300 MT/month. The plant had two 6.0 TPH capacity
Boilers of 10.54kg/sq cm (WP). The plant had been in operation for the last 10 years.
In the Pre-Audit Scenario it was discovered that the average furnace oil (F.O.) consumption was 10-
11KL, with a steam consumption of 130 TPD. The average Steam to Fuel ratio (S: F) was 11.8 with a
Feed Water (FW) temperature of 70-90ºC (Live steam in Condensate return). The average
Condensate Return from recoverable condensate was 59% (67 TPD) with O2 content in the flue
gasses between 4% and 6% and Stack temperature in the range of 220º-240ºC.
Sizing 5 TPD
Post Audit, based on our findings we devised a phase wise implementation to reduce FO consumption
thereby reducing costs.
Now Earlier
Average F.O. consumption 8.0-8.5 KL 10-11 KL
Average Steam Consumption 96-100 TPD 130 TPD
Average S:F ratio 12.1 11.8
Average FW Temp (No Live steam 65ºC 70º-90º C
in condensate return)
Average Condensate Return from 90% 59 %
recoverable condensate
Average O2 % in flue gas 3% 6% and 4%
Average Stack Temp 200º -210ºC 220º-240ºC
Yet there are more opportunities to bring down the fuel costs. Below are a few things we can still work
on;
Blow Down Heat Recovery System
Auto Temp. Control in yarn/fabric dyeing
Pressure controls
Proposal for Re Audit accepted and order is in process
Objective to save 1KL per day fuel more