DESIGNING AN ELECTRICAL ENERGY
CONSERVATION PROGRAM IN A WET PROCESSING
FOR A LOCAL TEXTILE INDUSTRY
ALEEM BUTT
INTRODUCTION
• Energy conservation commonly abbreviated as ENCON
according to (Oxford Dictionary of Abbreviation, 1998) is the
act of using energy in a more efficient and effective manner.
SIMPLE CONCEPT OF ENERGY
EFFICIENCY AND CONSERVATION
WHAT DOES ENERGY CONSERVATION DO
• Reducing the emission of greenhouse gases which contribute
to global warming
• Also saves costs for individuals and businesses, giving them
higher productivity and enhanced profitability due to cost
savings from energy bills.
• promote economic security and sustainability.
WHY ENERGY CONSERVATION IS IMPORTANT
FOR DEVELOPING COUNTRIES
• Energy conservation (ECON) becomes critically important for
the third world countries like Pakistan, where the energy
crises, rising energy costs and therefore efficient energy
equipments are of significant concern to both the industry and
the utilities.
• Pakistan ranks 30th in terms of world energy consumption in
year 2006 (BP, 2006).
STUDY DYNAMICS
• Industrial Sector – Major Power Consumption
• Textile – Major industrial Sector
• Wet Processing - Desizing, Scouring, Bleaching, Mercerizing, Singeing, Raising, Calendaring, Equipment's
Shrinking, Dyeing,
Finishing and Printing
•
•
•
•
•
•
Motors
Compressors
Lighting Systems
Air Conditioning Systems
Ventilation System
Computers Printers
Under Study
INDUSTRIES UNDER STUDY
• As study sample, we have taken 2 industries
1) MK Sons Textile 2 KM Khurruanwala, Faisalabad
2) Kohinoor Textile Mills Manga Raiwind Road Lahore
AIMS & OBJECTIVES
• Implement potential general and technical conservation
strategies after evaluating energy usage patterns
• Reduction of actual consumption of energy without process
design modification.
• Preparation of management plans and strategies to maximize the
system efficiency and effectiveness of energy inputs.
• Environmental protection by reduction in green house gas
emissions through energy conservation and reduce industrial
carbon emissions by increasing energy efficiency.
AIMS & OBJECTIVES
• Gaining monitory direct benefit in terms of minimizing the energy bills
expenditure, maximizing the productivity and profitability.
• Causing the indirect benefits for the country in terms of energy
conservation in current energy crises situation to promote economic
security.
• Promoting best management practices that can trigger chain of relevant
energy conservation along with boosting the productivity, efficiency and
effectiveness.
METHODOLOGY
INSTRUMENTATION
•
•
•
•
•
•
•
•
Lux Meter
Electric Power Demand Analyzer
Power Factor Meter
Voltmeter
Ammeter
Air Flow Meters
Voltmeter
Tachometer
RESULTS & DISCUSSION
• Electrical Utility Cost in MK Sons Textile Mill
MK SONS TEXTILE MILL (WET PROCESSING)
Quantity
Total
Load
Cost of
Electricity
(KW)
(Rs./day)
Cost of
Electricity
(Rs./Year)
Sr.
No.
Name of
Equipment
Machinery
Type
1
Motors
Bleaching
Plant
102
250
44750/-
2
Motors
Merchandizing
79
97
17363
3
Motors
Pud Steam
Cum
Washing
80
140
4
Motors
Senging /
Desizing
14
44
5
Motors
Dyeing
Jiggering
06
66
11814
4,170,342
6
Motors
General
Exhaust
Ventilation/
Fans
02
2.2
394
13,9082/-
7
Compressors
Compressor
04
4
716
2,52748/-
8
Fluorescent
Lamps
Fluorescent
Lamps
400
18
3222
11,37,366/
-
9
Computers
and Monitors
Computers,
Monitors
inside small
offices in
production
hall (based
on 12 hours
operation)
12
3.9
698
10
Printers
(during
Printing
Mode)
Printers
inside small
office in
production
hall (based
04
1
(Average
of peak and
off peak
(Nos.)
25060
7876
based on
353 days
15,79,675
0/6,12,9139/
8,84,6180/
2,780,228
2,46,394/-
9.0
3,177/-
RESULTS FORM THE IMPROVEMENT AND
CONSERVATION ANALYSIS
•
•
•
•
•
•
•
•
Opportunities Dynamics
Day Light Harvesting
Good House Keeping
Improving ILER- Msurement
Improving Compressors- Environment
Replacing Motors
Improving Ventilation Systems
% Energy Efficiency Improvements
DAY LIGHT HARVESTING
Measures Taken in MK Sons Textile
• Changing on Roof Glass & Sliding Windows
• Windows frame painted light in Color and anti glare
finish
• The measures reduces the lighting load upto 50 % that
saves 3300 KW/Per Year almost Rs. 25000/- per Year
DAY LIGHT HARVESTING
Measures Taken in Kohinoor Textile
• Windows glass replacement of slider windows
• Photo sensors has been installed with the lighting systems
• 15 % Saving from windows glass replacement and 5 % from
photo sensors. Total 20 % saving Energy save 9000 KW with
amount 70,000 per year having pay back of photo sensors 4
years
PROVISION OF TOP LIGHTING IN MK SONS TEXTILE
GOOD HOUSE KEEPING MEASURES
• Following Behavioral practices were adopted in both
textile which saves almost 70 % of energy in
lightening, computer appliances and air conditioners.
• Proper cleaning and staff motivation to turn off lights
of unoccupied areas saves almost 1 % of energy
• Switching off the appliances when not in use and
proper plug out during night time saves almost 8 % of
energy
• 60 % of energy is saved from AC by proper insulation
of rooms, cleaning air filters and regulating AC at 26 C
GOOD HOUSE KEEPING
• The wastages and leakage from lighting were Rs. 12000 to
15000 (1600-2000 KW), computers appliences Rs. 18000 to
20,000 (2400-2600 KW) and air conditioning systems 115,000
to 120,000 (15000-16000 KW) per year is saved by changing
and managing human behavior.
ILRE MEASUREMENT
• The overall lighting performance was calculated by finding
ILER (Installed Load Efficacy Ratio) with reference to the
energy wastages
Sr.
No
Description
Unit
Reading
1
Date
26/04/2012
2
Time of Measurement
1:00 PM to 6:00
PM
3
Room Identification
Wet Processing
Hall
4
Type of Activity
Wet Processing
5
Number of Lamps
5
6
Length of the part of hall
M
11
7
Width of the part of hall
M
8
8
Area of Part of hall
m2
88
9
Height of the lamp
M
3.1
10
Room Index (in accordance with room
index formula)
1.50
11
Number of points taken for Lux
16
12
Average part of Hall
13
Measured and Estimated circuit
Power, P
W
250
14
Watts Per Meter Square
W/m2
2.84
15
Lux Per Watt Per Meter Square
Lux/W/m2
52.81
16
Target Lux
Lux/W/m2
58
17
Installed Load Efficacy (ILER)
Lm/W
0.91
luminance, F
Lux
150
ILRE MEASUREMENT
• The cost of annual energy wastage in terms of lighting in wet
processing hall of MK Sons Textile Mills was about 190 KW
per year which cost about Rs.1463 per year with the
production capacity 2.8 million mili meter per month as
compared to Kohinoor Textile Mills where it was 762 KW per
year which cost about Rs. 5715 per year with the production
capacity 1.8 million mili meter per month.
IMPROVEMENTS IN ILER BY MEASURES
• Reflectors cleaned and painted that improves the luminary efficacy.
• Lamps height was reduced from 2.7 to 2.0 meters that improved the room
index from 1.71 to 2.31
• Walls white washed and proper cleaning of floor
• The above measures improved the average Lux value from 140 to 230 and
reduced the annual energy wastage from 762 KWH to 150 KWH and it
saved the cost of almost Rs. 5000/- per year in kohinoor textile
• In the same pattern improvements measures had also been taken in MK
Sons Textile Mills which further reduced the energy consumption by 190
KWH per year and saved Rs. 1463 per year.
COMPRESSORS
•
•
•
•
Wastages from Free Air Delivery Test (FAD)
Inefficiency in compressors
MK Sons Textile – 0.659 KW/h -Rs. 41640 per year.
Kohinoor Textile Mills - 1.86 KW/h - Rs. 120810 per year.
MEASURES IN COMPRESSORS
• Small Sheltered room
• Cool Dry Air and ducting between air intake and compressors
• After implementing Measures
The energy savings in MK sons textile were 0.319 KW/h and in
Kohinoor textile 1.34 KW/h. With the subsequent cost saving of
Rs. 21459/ year at MK Sons Textile Mills and Rs. 84575/ year at
Kohinoor Textile Mills respectively.
LEAKAGE TESTING OF COMPRESSORS
Parameter
Unit
Q
m3/min
0.5
2.49
T
Min
1.5
2.0
T
Min
7.5
11.5
System Leakage
m3/min
0.083
0.368
Leakage Quantity Per Day
m3/day
119
531.2
Specific Power For
Compressed Air Generation
KWh/m3
0.04
0.053
KW/day
4.76
28.1
(Measured Power During Loading ÷
(Compressor Capacity × 60)
Energy Lost due to Leakage
Per Day
(Specific Power for compressed air ×
Leakage quantity per day)
MK Sons Textile Mills Kohinoor Textile Mills
LEAKAGE TESTING COMPRESSORS
• 3.6 % air leaks were detected in MK Sons Textile Mills
• 11.3 % air Leaks were detected in Kohinoor Textile Mills
ENERGY SAVE AFTER IMPROVEMENTS OF
LEAKS IN COMPRESSORS
• All the leaks in relief valves, joints, quick release couplings,
shut off valves etc were repaired. After improvement of air
leaks The total energy saved in MK sons Textile Mills was
4.756 KW/day and in Kohinoor textile it was 28.0 KW/day
and the cost of energy saved has been Rs. 12491/ year and Rs.
73635/ year respectively.
MOTORS
• Rewound motors in both industries were replaced with energy
efficient motors and they have given immediate benefits. 40 Nos.
rewound motors in MK Sons Textile Mills were replaced with
energy efficient motors. The total investment was almost Rs.
250,000/- which would save Rs. 80,000 per year with capital
investment pay back is just 3 years. Similarly in Kohinoor textile
25 Nos. rewound motors were replaced with energy efficient
motors having investment Rs. 150,000 which would save Rs.
50,000 per year and the pay back of capital investment is 3 years.
VENTILATION SYSTEM
VENTILATION RESULTS
Sr.
Industry
No.
Indoor CO2
Outdoor
Difference
CFM per
Level
CO2 Level
of Indoor
Person
(ppm)
(ppm)
and
(10500÷
Outdoor
Difference of
Levels
indoor and
outdoor levels)
(ppm)
1
MK Sons Textile
680
345
335
31.3
540
360 ppm
180
58.3
Mill
Kohinoor Textile
Mill
ENERGY IMPROVEMENTS IN
VENTILATION SYSTEMS
• Variable speed drivers had been installed on the motors of
General Exhaust Ventilation Systems which enabled the
adjustments of CFM per person set at 25 CFM in both
industries.
• These measures have resulted in energy saving of 0.5 KW/hr
i.e. equivalent to Rs. 31,727/ year and 0.7 KW/hr i.e.
equivalent to Rs. 44,418/ year in M/S MK Sons and M/S
Kohinoor Textile Mills respectively.
COST BENEFIT ANALYSIS
No. of Obs.
Energy Saving Measures
Investment
Rs.
Savings
Rs./Year
Pay Back Period (Years)
1
Changing of dark colored mirror of windows and roof aperture to ultra clear and
clear mirror in MK Sons Textile Mill. Properly positioned mirror and painted
light color to the windows frames
40,000/-
25000/-
2
2
Provision of the slide windows (Harvesting Day Lighting) and installation of
photo sensors in Kohinoor Textile Mill
250,000
70,000/-
4
3
Energy Conservation by cleaning windows & floors and encouraging staff to turn
off lights of unoccupied areas
Nil
10,000-15,000/-
-
4
Turning off the appliances like Computers, monitors, photocopiers, and printers
etc when not in use and properly plugged out over night. Also Battery chargers
were unplugged when batteries were fully charged or charger was not in use
Nil
19000/-
-
5
Regulating Air Conditioner thermostat 26 ºC instead of 20 ºC
Nil
114372/-
-
6
Properly cleaning of reflectance and lowering of lamp height form 2.7 meters to
2.0 meters in Kohinoor Textile Mill.
10,000/-
5000/-
2 Years
7
Replacing of Conventional Fluorescent Lamp with LED lighting system in
Kohinoor Textile Mill if replaced all in the hall
1407000/-
507791/-
2.7 Years
8
Replacing of Conventional Fluorescent Lamp with LED lighting system in MK
Sons Textile Mill if replaced all in the hall
140,0000/-
619515/-
2.2 Years
No. of Obs.
Energy Saving Measures
Investment
Rs.
Savings
Rs./Year
Pay Back Period (Years)
9
Improving FAD of the compressor by building small sheltered
room for intake of cool and dry air in MK Sons Textile Mill
40,000/-
21459/-
1.9 Years
10
Improving FAD of the compressor by building small sheltered
room for intake of cool and dry air in Kohinoor Textile Mill
60,000/-
84575/-
0.7 years
11
Repairing of the air leaks in joints, valves, couplings etc and
maintenance of the compressor in MK Sons Textile Mill
-
12491/-
-
12
Repairing of the air leaks in joints, valves, couplings etc and
maintenance of the compressor in Kohinoor Textile Mill
-
73635/-
-
13
Replacing Rewound motors with energy efficient motors in MK
Sons Textile Mill
250,000/-
80,000/-
3.1 Year
14
Replacing Rewound motors with energy efficient motors in
Kohinoor Textile Mill
150,000/-
50,000/-
3 Years
COMPARISON OF EFFICIENCY OF ENERGY EFFICIENCY
IMPROVEMENTS MK SONS TEXTILE MILL V/S KOHINOOR TEXTILE
MILLS
Sr.
1
2
3
Conservation
Measure
Day Light
Harvesting
Energy
Conservation by
cleaning windows
& floors and
encouraging staff to
turn off lights of
unoccupied areas.
Turning off the
appliances like
Computers,
monitors,
photocopiers, and
printers etc when
not in use and
properly plugged
out over night. Also
Battery chargers
were unplugged
when batteries were
Cost of Energy
(Before)
MK Sons Textile
Cost of Energy
(After)
MK Sons
Textile
Energy Efficiency
Improve-ments
(%)
MK Sons
Textile
Cost of Energy
(Before)
Kohinoor
Textile
Cost of Energy
(After)
Kohinoor Textile
Energy Efficiency
Improve-ments
(%)
Kohinoor Textile
155078/-
77539
50
429123
343299
20
9988
9789
98
12445
12072
97
18667/-
17734
95
20677/-
2067
90
COMPARISON OF EFFICIENCY OF ENERGY EFFICIENCY
IMPROVEMENTS MK SONS TEXTILE MILL V/S KOHINOOR
TEXTILE MILLS
Sr.
Conservation
Measure
Cost of Energy
(After)
MK Sons
Textile
Cost of Energy
(Before)
MK Sons Textile
Energy Efficiency
Improve-ments
(%)
MK Sons
Textile
Cost of Energy
(Before)
Kohinoor
Textile
Cost of Energy
(After)
Kohinoor Textile
Energy Efficiency
Improve-ments
(%)
Kohinoor Textile
4
Regulating Air
Conditioner
thermostat 26 ºC
instead of 20 ºC
114,372
0
100
194,239
0
100
5
Improving ILER
by lowering lamp
height
1501
756
50
6020
1020
83
6
Efficiency
improvement in
FAD of the
compressors
41640
20181
48.4
120810
36235
29.9
7
Air Leakages in
Compressors
12518
12491
88
73898
73635
84
8
Replacement of
Rewound Motors
6311640
6231640
1.3
3786984
3750984
1.0
CONCLUSION
• The total energy efficiency achieved from all the measures has
been 61.4 % and 58 % in MK Sons Textile and Kohinoor Textile
respectively.
• Both firms do have the tendencies for further energy efficiency
progress up-to 25-30% but that do require monetary investments
in-terms of sophisticated technical and human resource
development.
• About Rs. 10 – 20 Million/ year savings in industry in terms of
money is achieved through these simple efficiency measures
CONCLUSION
• This study concluded that there many opportunities of energy
savings, which are existent in this sector but due to lack of
effective governance and energy conservation policies,
deficient worker’s awareness, training and motivation plans,
huge amount of energy is wasted that is reflected in terms of
huge financial and economic loses to the industry and to the
country.
THANK YOU