Evaluation of Cotton Textile Supply Chain Programme and Potential for Scale-up in Hyderabad, India
LOW GRADE WHU POTENTIAL- TEXTILE SECTOR
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Transcript of LOW GRADE WHU POTENTIAL- TEXTILE SECTOR
LOW GRADE WHU POTENTIAL- TEXTILE SECTOR
12-Aug-14R Rajmohan
Partnership to Advance Clean Energy-Deployment (PACE-D)(PACE-D)Technical Assistance Program
CONTENTS
• Process Flow • Sources of Low Grade Waste Heat • Overall Potential• WHU Solutions • Case Studies
Textile Processing : Illustrative for Cotton Prints
Source: Cluster Manual Pali Textile Cluster; BEE
Boiler
Thermopac
Process Utilities
Air compressors
Textile Processing : Pali Textile cluster- Quick overview
Source: Cluster Manual Pali Textile Cluster; BEE
Sl No Item Target Efficiency
1 Sources of Energy Electricity from Grid & Pet Coke
2 Energy Use pattern – Pet Coke
5 to 7 TPD (Power process)1 to 1.5 TPD (Small Units)
3 Energy Use pattern- Electricity
Power Process: 3000 kWh/DayOnly printing: 160-500 kWh/Day
4 Specific energy consumption ( Processing of polyester & Printing)
Electricity: 1.2 kWh/KgThermal: 15000 Kcals/Kg
Sources of Waste Heat
DryingDrying StenterStenter
DyeingDyeingJiggerJigger DryingDryingJiggerJiggerSingeingSingeing
Stretching
Stretching
BoilerBoiler
Low Grade WH: Overall PotentialEffluents
Quantity: 3000 Kg/CycleTemperature: 70 Deg C
WHR potential: 120000 Kcals/Cycle
Jiggering & Swing SteamReject condensate: 120 Kg/Hr
Temperature: 70 Deg CWHR potential: 6300 Kcals/Cycle
Drying & Jiggering SteamReject Effluent: 200 Kg/Hr
Temperature: 70 Deg CWHR potential: 12000 Kcals/Cycle
Drying & Jiggering waterReject condensate: 3500 Kg/Hr
Temperature: 70 Deg CWHR potential: 210000 Kcals/Cycle
Dyeing @ 140 Deg C
Reject effluent: 5000 Kg/Hr
Temperature: 100 Deg C
WHR potential: 408000
Kcals/Cycle
Stretching @ 120 Deg C
Reject Effluent: 123 Kg/Hr
Temperature: 100 Deg C
WHR potential: 1230 Kcals/Cycle
WHU- Overall potential0.323 Kg of Fuel/Kg of Cloth
Annual fuel savings: 93 MT/YearCost savings: 11.2 Lac Rs/Year
Mill producing 37 Kg of cloth/Hr
Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases - Economizer
• Waste heat recovery device • Usually used in boilers to recover waste heat from flue gases.• Recovered heat is used to pre-heat feed water to boiler• Useful where water feeding to boiler is continuous
BoilerFlue Gas
ECO
To Chimney
Feed water Pump
200 Deg.C
T1= 30 Deg.C
150 Deg.C
T2 = 50 Deg.C
Low Grade WHU Technologies: Waste heat recovery from Boiler/Thermopac Flue gases – Air Preheater
Boiler/ Thermo pac
Flue GasAPH
FD Fan
200 Deg.C
T1= 30 Deg.C
150 Deg.C
T2 = 80 Deg.C
Combustion air
• Waste heat recovery device • Usually used in boilers/Furnaces to recover waste heat from flue gases.• Recovered heat is used to pre-heat combustion air to boiler/Furnace• Useful where Economizer exists already
Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater (S&T heat exchanger)
• Waste heat recovery device • Usually used in boilers to recover waste heat from flue gases.• Recovered heat is used to pre-heat boiler feed water• Useful when the feed water flow to the boiler is not continuous
Boiler
Flue Gas S& T
H E To Chimney
Water Pump
Feed Water Tank
Feed water Pump
Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater- Heat pipe heat exchanger
• Waste heat recovery device • Usually used in boilers to recover waste heat from flue gases.• Recovered heat is used to pre-heat feed water to boiler• Useful to recover heat where Delta T is lower
Low Grade WHU Technologies: WHR from Boiler Blow Down – Flash Steam Recovery & Heat recovery from BD condensate
• Flash steam recovery from Boiler blow down • Heat recovery from the condensate of the blow down• Recovered heat is used to pre-heat Boiler feed water/ other hot water
requirements
Low Grade WHU Technologies: Condensate Recovery
• Condensate recovery device • No mechanical pumping• Recovered condensate is used as boiler feed water• Savings of both water and heat
Low Grade WHU Technologies: Heat Recovery from Hot effluents
• Waste heat recovery device • Used to recover heat from process effluents
Low Grade WHU Technologies: Heat Recovery from Hot Vapours
• Hot vapors from sources like Stenters are the heat source• Used to either generate hot water or to heat the fresh air to the source
equipments
CASE STUDY 1 : Waste heat recovery system in Boiler
Item Unit ValueAs Is To be
Flue gas temperature Deg C 204 180GCV of fuel Kcals/Kg 8000 8000Fuel used MT/Year 1260 1210Savings in fuel MT/Year 50Cost of Fuel Rs/MT 12000 12000Savings n Energy cost Rs/Year 600000Investment Rs 300000Simple Payback period Year 0.5
Savings by Installing Waste heat recovery System in Boiler
CASE STUDY 2 : Waste heat recovery system in Thermopac
Item Unit ValueAs Is To be
Flue gas temperature Deg C 250 180GCV of fuel Kcals/Kg 8000 8000Fuel used MT/Year 1800 1710Savings in fuel MT/Year 90Cost of Fuel Rs/MT 12000 12000Savings n Energy cost Rs/Year 1080000Investment Rs 500000Simple Payback period Year 0.5
Savings by Installing Waste heat recovery System in Thermopac
CASE STUDY 3 : Waste heat recovery –Boiler Blowdown
Item Unit ValueAs Is To be
Quantity of water per blowdownLit 200 200No of blowdown per day Nos 5 5Total blowdown quantity Lit/Day 1000 1000Total heat recovery from blowdownKcals/Day 80000 80000Savings in fuel MT/Yr 3.4Savings n Energy cost Rs/Year 40800Investment Rs 50000Simple Payback period Year 1.2
Savings from Boiler blowdown heat recovery
CASE STUDY 4 : Waste heat recovery- Jet Dyeing Machine
Item Unit ValueAs Is To be
No of Jet Dyeing Machine Nos 3 3Steam consumption/Hr Kg/Hr 150 150Flash steam recovery potentialKcals/Hr 28800Savings in fuel MT/Yr 29.5Savings n Energy cost Rs/Year 354000Investment Rs 200000Simple Payback period Year 0.6
Savings from Heat recovery- Jet Dyeing Machine
CASE STUDY 5 : PHE – Heat Recovery from Jet Dyeing Machine (Sameer Synthetics)
Temp. of water drained : 85oCProposal : Collect hot water and use for pre-heating cold water stream used for process
CASE STUDY 2: Cost Benefit Analysis
Number of Machines in Operation 9
Quantity of Water Drained/Batch/Machine 400 l
Number of batches/day/machine 10
Water temperature at outlet of machine 80oC
Expected temperature of effluent at outlet of PHE 38oC
Expected energy savings 1,512,000 kCal/day
Equivalent Fuel Savings 189 kg/day
Equivalent Cost Savings 6.8Lakh Rs/year
Investment 4 Lakh Rs
Simple Payback Period 7 Months