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Semester: 6th
Heat generated through the combustion of fuel is utilized to generate steam from
water in a boiler and to heat thermal fluid in a thermal fluid heater. Heat of the steam and
the thermal fluid is utilized in various textile processors. Ever escalating fuel cost has
increased the cost of heat energy to a considerable extent, which is one of the important
factors contributing to the higher processing cost, and hence the production cost of textile.
Higher production cost thin profit margins; tough global competition collectively has posed a
serious problem for survival of Textile Industry.
Therefore, every possible step has to be taken to lower the production cost. Heat
economy i.e. conservation of thermal energy is a major option in this regard. Heat economy
is nothing but efficient generation and utilisation of heat energy. Scope for heat economy i.e.
conservation of thermal energy exists during generation and utilization of thermal energy,
recovery of waste heat, etc. Some general suggestions for heat economy have been given
in the following:
STEAM GENERATION
Monitor the Combustion Efficiency and other related combustion parameters like
O2, stack
temp. etc. of the boilers on regular basis and take corrective actions immediately
to attain the optimum efficiency.
Load the boilers to 80-85% of their rated capacity, for optimum performance.
Avoid frequent start-stop of the boilers.
Avoid banking losses of a boiler; operate only the requisite numbers of boilers as
per the demand for steam.
Limit the boiler steam pressure to the requirement of the machines, giving due
allowance for the pressure drop in the steam distribution system.
Adjust boiler blowdown keeping in view the TDS levels prescribed for different
types of boilers.
UTILISATION OF STEAM
General Background
Tuning of the boiler for reducing excess air and thorough cleaning of its heat transfer
surfaces: thermal efficiency improvement from 82.5 to 84.0%
Incorporating automatic blowdown control system at boiler; 40% blowdown quantum
reduced.
Repair of pressure reducing valves installed in three main steam supply lines.
Attending malfunctioning steam traps (15 Nos.)
Closing trap by-pass line valves ( 23 Nos.)
Providing individual trapping system instead of group trapping for drying range
machines.
Recovery of condensate from 9 dyeing machines, 2 drying range and 1 zero-zero
machine and using it as boiler feed water.
Plugging steam leakages (53 Nos.).
Lagging of cylinder ends of both the drying range machine. Lagging of hot bare
surfaces in thermic fluid heating system.
Overhauling of TPA-10 Thermic fluid heater; its thermal efficiency improved from 73
to 79%.
Fuel Saving : 350 KL (Rs.39 lakhs)/Annum.
Fuel Saving as % of consumption : 7.8%
CASE STUDY – 2
General Background
Proper tuning of the thermic fluid heater for reducing excess air; thermal efficiency
improved from 55% to 65%.
Lagging of hot bare valves in thermic fluid heating system (66 Nos.)
Plugging steam leakages (6 Nos.).
Fuel Saving : 400 MT(Rs.11.6 lakh)/Annum.
Fuel saving as % of consumption : 16.50%
CASE STUDY – 3
General Background
Adjusting of air dampers in the thermic fluid heater; its thermal efficiency improved
on the spot from 52% to 58%.
Lagging of hot bare valves in thermic fluid heating system (89 Nos.)
Plugging steam leakages (4 Nos.).
Shutting trap by- pass valves (3 Nos.)
Attending malfunctioning traps(3 Nos.).
Attending punctured main condensate line
Fuel Saving : 470 MT (Rs.6.8 lakh)/ Annum.
Fuel saving as % of consumption : 8.50%