Design Of Heat Recovery System to Recover Heat from the
Waste Water Generated during Dyeing Process in Textile
Industry.
A Mini-Project Submitted for the partial fulfillment of the Degree of Bachelor of
Technology in
Mechanical and Automation Engineering, May 2025
By
Meera Dodamani
Sarthak Chatake
Mallikarjun Kemshetti
2206111031
2206111024
2206111015
Under the Guidance of
Dr. S. S. Bansode
Department of Mechanical Engineering
Walchand Institute of Technology, Solapur
Affiliated to Punyashlok Ahilyadevi Holkar Solapur
University,
Solapur, Maharashtra, India.
1
CERTIFICATE
This is to certify that the Mini-project entitled “Design Of Heat Recovery
System to Recover Heat from the Waste Water Generated during Dyeing
Process in Textile Industry”, has been carried out and is submitted by students
for the partial fulfillment for the award of the degree of Bachelor of
Technology in Mechanical and Automation Engineering.
Name
USN
Meera Dodamani
2206111031
Sarthak Chatake
2206111024
Mallikarjun Kemshetti
2206111015
Dr. S. S. Bansode
Dr. Bhagyesh B. Deshmukh
Guide
Head, Dept. of Mech. Engg.
Dr. Vijay A. Athavale
Principal
2
ACKNOWLEDGEMENT
We take this opportunity to express our heartfelt gratitude to Dr. S. S. Bansode,
our project guide for his constant encouragement, expert guidance, and valuable
suggestions throughout the course of this mini-project. His insights and support
were crucial in shaping the direction and outcome of our work on “Design Of
Heat Recovery System to Recover Heat from the Waste Water Generated
during Dyeing Process in Textile Industry.”
We would also like to sincerely thank Dr. Bhagyesh B. Deshmukh, Head of
the Department of Mechanical Engineering, for his support and for facilitating
a positive and resourceful academic environment that enabled us to carry out
our project successfully.
We are thankful to the faculty and technical staff of the department for their
assistance and cooperation during various stages of the project. Their timely
help and feedback enriched our learning experience. Our sincere appreciation
also goes to our classmates and peers for their encouragement and constructive
discussions that helped us refine our ideas.
Meera Dodamani
Sarthak Chatake
Mallikarjun Kemshetti
iii
ABSTRACT
In the textile industry, particularly in the dyeing process, a substantial amount of thermal
energy is consumed to heat water. A large portion of this energy is lost as hot wastewater
discharged into drains, contributing to both energy wastage and thermal pollution. This
project aims to design and analyze an effective heat recovery system that captures the
residual heat from wastewater and utilizes it to preheat incoming cold water, thereby
improving overall energy efficiency.
The proposed system focuses on practical application in small to medium-scale textile units,
especially those that currently operate without any form of energy recovery. The design is
based on compact heat exchanger principles, ensuring cost-effectiveness and ease of
integration into existing infrastructure. Through thermal analysis and performance
evaluation, the project seeks to determine the feasibility and potential energy savings of the
system.
The successful implementation of this heat recovery system is expected to reduce fuel
consumption, lower operational costs, and promote sustainable practices in textile
manufacturing. The project not only addresses energy efficiency but also contributes to
environmental conservation by minimizing waste heat discharge into water bodies.
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List of Figures
Figure
No.
Name of the Figure
Page
No.
1.
Design of Heat Recovery System
xvi
2.
Analysis of Heat Recovery System
xviii
v
ACKNOWLEDGEMENT................................................................... .+iii
ABSTRACT.............................................................................................. iv
INDEX ....................................................................................................... v
LIST OF FIGURES ................................................................................ vi
Serial
No.
Page No.
Index
1
INTRODUCTION
8
2
LITERATURE REVIEW
2
3
OBJECTIVES
3
4
NECESSITY OF WORK
4
5
METHODOLOGY
5
6
DESIGN OF HEAT RECOVERY SYSTEM
6
7
ANALYSIS OF HEAT RECOVERY SYSTEM
7
8
9
PROJECT PROGRESS PLAN
REFERENCES
8
10
vi
1. INTRODUCTION
The textile industry is one of the largest consumers of water and energy. A significant
portion of this energy is used in the dyeing process, where large volumes of hot water
are required. This proposal outlines a project to implement a heat recovery system for
dyeing water in the textile industry. The primary objective is to reduce energy
consumption, lower operational costs, and minimize environmental impact by
recovering and reusing heat from the dyeing process. This approach can significantly
reduce energy consumption, lower greenhouse gas emissions, and provide cost savings
for textile manufacturers. The figure 1 below shows the typical dyeing process being
followed in the textile indusrty. I view to carry out the current project work a visit to
some of the textile units that are engaged in dyeing process was carried out and it was
found that the waste water after carrying out the dyeing process is let out in the open
environment at an approximate temperature ranging from 60 degrees to 70 degrees. It
can be mentioned that the amount of heat contained by the waste water needs to
recovered, which can be further utilized for pre-heating of water being supplied to
boiler. The summary of the observations during the visit are as below.
Industries
Water Inlet Temp
Water Outlet Temp Water
Used
Session
Textile 1
120°C – 130°C
60°C-70°C
500-600 L
Textile 2
95°C-110°C
55°C-65°C
300-400 L
Textile 3
80°C-120°C
65°C-75°C
800-900 L
Textile 4
90°C-110°C
50°C-60°C
500-600 L
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Per
2.
LITERATURE REVIEW
The textile industry is one of the most energy-intensive manufacturing sectors
globally, with the dyeing process alone consuming a substantial portion of total
energy. This high consumption is largely due to the thermal energy required to
heat large volumes of water used in dyeing. Given this, recovering heat from the
wastewater generated during dyeing processes has emerged as a promising
solution for reducing energy waste, operational costs, and environmental
impact.
1. Energy Consumption in Textile Dyeing
Research has consistently highlighted the significant energy demands associated
with textile dyeing. Hasanbeigi and Price (2012) emphasize that dyeing
operations contribute to as much as 30-40% of total energy consumption in
textile plants. The inefficiencies arise primarily from the discharge of hot
wastewater and poor insulation, as well as outdated process controls. Similar
findings by Zhang et al. (2013) indicate that energy savings of up to 20% can be
realized by improving heat management practices, particularly in wastewater
handling.
2. Heat Recovery Technologies
Various technologies have been proposed and implemented to address this
inefficiency. Heat exchangers are among the most widely used systems, wherein
the thermal energy from hot effluent water is transferred to the incoming cold
water, thereby reducing the heating load on boilers. Johansson (2014) reports
that such systems can reduce energy consumption by 20-30% in a typical textile
plant.
Advanced solutions such as heat pumps have also been explored. According to a
2007 Energy Star report, these systems are capable of extracting low-grade heat
from wastewater and boosting it to usable temperature levels. While the initial
investment is relatively high, the return in energy efficiency and long-term cost
savings makes it a viable option for large-scale operations.
In addition, waste heat boilers have gained traction in large facilities. These
systems utilize the latent heat of exhaust gases for steam generation, which can
be reused within the same process or across other operations in the plant (Saidur
et al., 2010).
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3. Industry-Specific Case Studies and Best Practices
Case studies by WRAP (2012) and the European Commission (2017) further
reinforce the value of heat recovery. Facilities implementing custom-designed
heat recovery systems reported not only energy savings but also reductions in
greenhouse gas emissions and improved regulatory compliance.
UNIDO and the International Finance Corporation have also published
guidelines and frameworks to encourage sustainable practices in textile
manufacturing. These documents advocate for retrofitting existing plants with
energy-efficient equipment and integrating closed-loop water systems that not
only recover heat but also enable partial reuse of process water.
4. Identified Gaps and Relevance to Current Project
Despite the existing body of work, several gaps persist. Many heat recovery
solutions are either too costly for small-to-medium enterprises (SMEs) or
require complex integration into existing infrastructure. Additionally, there is
limited research focusing specifically on dyeing units handling materials like
terry towels—an area that this project aims to address.
The current project intends to design a heat recovery system tailored to the
operational scale and needs of typical Indian textile units, as observed during
site visits. These units, operating without any form of exhaust or heat recovery,
represent an untapped opportunity for energy optimization. By leveraging
practical, cost-effective engineering solutions, this project seeks to demonstrate
the feasibility of implementing heat recovery in a simplified, automated manner
suitable for widespread adoption in the Indian context.
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3.
OBJECTIVES
• To study the dyeing process.
• To design a heat recovery system for the dyeing process in textile industry
• To analyze the designed heat recovery system.
• To reduce energy consumption
• To contribute toward sustainable manufacturing practices
4.
NECESSITY OF WORK

Large amounts of hot water are wasted in the textile dyeing process.

No heat recovery system is used in most small to medium textile units.

This leads to high energy losses and increased fuel costs.

Discharge of hot water causes thermal pollution and environmental harm.

There is a need for a low-cost, efficient system to recover and reuse waste heat.

The project promotes energy savings and supports sustainable manufacturing.
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5.
METHODOLOGY
PROBLEM STATEMENT AND OBJECTIVE
INTRODUCTION
LITERATURE REVIEW
DEVELOPMENT OF 3D CAD MODEL OF HEAT
RECOVERY SYSTEM
ANALYSIS OH HEAT RECOVERY SYSTEM
CONCLUSION
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6. DESIGN OF HEAT RECOVERY SYSTEM
This design is a Shell and Tube Heat Exchanger, primarily constructed using
durable metal materials such as stainless steel or carbon steel for high thermal
efficiency and corrosion resistance. The structure comprises a cylindrical shell
housing a bundle of parallel tubes that are fixed in position using baffles and
support plates. Flanged nozzles are provided for fluid inlet and outlet, ensuring
secure connections and ease of maintenance. The front red section is the channel
head, where one fluid enters and exits the tubes, while the outer shell allows
another fluid to flow over the tubes, facilitating efficient heat exchange between
the two. The entire assembly is supported on a set of strong steel base brackets
to maintain stability and alignment during operation. This type of heat
exchanger is commonly used in industries such as power plants, oil refineries,
and chemical processing, where managing heat transfer efficiently is essential.
Specifications of Heat Recovery System:
 Tube Length : 580 mm
 Shell Diameter : 166 mm
 Inlet Tube Length : 34 mm
 Outlet Tube Length : 34 mm
 Number Of Pipes : 84
 Pipe Diameter : 8 mm
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Fig 1 : Design of Heat recovery system.
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7. CFD ANALYSIS HEAT EXCHANGER
Computational Fluid Dynamics (CFD) analysis of a shell and tube heat exchanger is an
essential approach to understanding the heat transfer mechanisms and flow behavior within
the system. This simulation aids in optimizing the thermal performance, enhancing
efficiency, and ensuring operational reliability across a wide range of industrial applications.
The CFD analysis focuses on the behavior of both hot and cold fluids interacting within the
exchanger, helping improve design accuracy and predict performance under realistic working
conditions.
The parameters considered for CFD Analysis:
Analysis Type: Internal flow
Mesh Type: CAD-based Boolean mesh for precise geometry modeling
Boundary Conditions:
Hot Fluid Inlet Temperature: 87°C
Cold Fluid Inlet Temperature: 20°C
Hot Fluid Inlet Velocity: 2.5 m/s
Cold Fluid Inlet Velocity: 1.5 m/s
Operating Pressure: 1.01325 bar (atmospheric)
Material (Tubes): Stainless Steel / Optional Aluminum
Ambient Conditions: Adiabatic wall assumed, insulated environment
Initial Conditions:
Gravity: 9.81 m/s²
Fluid Properties: Water (or specific working fluid used in simulation)
Wall Temperature (initial): 25°C
CFD Results and Observations:
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As seen in the simulation results, the heat exchanger successfully transfers heat from the hot
fluid to the cold fluid across the tube surfaces. The hot fluid enters at 87°C and exits at 70°C,
while the cold fluid enters at 20°C and exits at 32°C, showing effective heat exchange
performance. The temperature distribution is clearly visualized through the color gradient,
where red indicates high temperature zones and blue represents cooler regions.
The velocity vectors demonstrate turbulent mixing inside the shell, which enhances
convective heat transfer. Baffle plates help direct the fluid flow over the tubes in a zig-zag
pattern, improving heat absorption efficiency. The temperature contours further confirm a
smooth and effective thermal gradient across the exchanger.
This CFD analysis enables designers to evaluate design efficiency, identify possible areas of
flow stagnation or pressure loss, and explore the potential of alternative materials such as
aluminum. Using aluminum, for instance, could enhance thermal conductivity while
reducing system weight, though considerations regarding corrosion and pressure resistance
must be taken into account.
Conclusion:
CFD analysis of this shell and tube heat exchanger model provides in-depth insights into
thermal behavior and fluid dynamics. It supports optimized design decisions, material
selection, and layout modifications. By using simulation tools like ANSYS and SolidWorks
Flow Simulation, engineers can predict real-world performance, minimize trial-and-error
prototyping, and ultimately design more efficient and reliable heat exchangers
for industrial use.
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Fig 3 : Analysis of Heat recovery system
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PROJECT PROGRESS PLAN
WEEK
WEEK
1&2
WEEK
3&4
WEEK
5&6
WEEK
7&8
ACTIVITIES
IDENTIFICATION
OF PROBLEM
LITERATURE
REVIEW
DESIGN
ANALYSIS
REPORT
WRITING
17
WEEK
9&10
WEEK
11&12
WEEK
13&14
WEEK
15&16
REFRENCES
1. Website: Lawrence Berkeley National Laboratory
Research Paper: Energy-Efficiency Improvement Opportunities for the Textile Industry
Authors: Ali Hasanbeigi
Publisher: U.S. Department of Energy
Book/Report: LBNL Report No. 3970E
Reference Link: https://eta-publications.lbl.gov/sites/default/files/lbnl-3970e.pdf
2. Website: Energy Efficiency Journal (Springer)
Research Paper: Saving energy in China’s industry with a focus on electricity: A review of
opportunities, potentials and environmental benefits
Authors: Hui Yue, Ernst Worrell, Wina Crijns-Graus, Wen Liu, Shaohui Zhang
Publisher: Springer
Reference Link: https://doi.org/10.1007/s12053-021-09979-4
3. Website: ResearchGate
Research Paper: Improving Industrial Energy Efficiency through the Implementation of
Waste Heat Recovery Systems
Authors: Kristine O’Rielly, Jack Jeswiet
Publisher: Queen’s University
Reference Link: https://www.researchgate.net/publication/280235115
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