Energy Consumption in industry project ideas

INTRODUCTION

Manufacturers face a growing global business environment, they want to reduce production costs without less production or quality. For public and private companies don’t like increasing energy costs. Technologies and practices have successful cost-effective investment in energy-efficiency. This is particularly important in the present era because energy-efficient technologies often include additional benefits, such as increasing the company's productivity or reducing water and/or content consumption.

Energy efficiency is a necessary component of the company's environmental strategy. End-of-pipe solutions can be costly and inefficient when energy efficiency is often a low-cost opportunity for emissions and emissions of other contaminants. In a nutshell, energy-efficient investment is the sound business strategy in today's production environment. Many countries have government policies and programs. However, there is some information about energy sources available for the energy management system to improve energy efficiency.

This project provides information on energy-efficiency technologies, problem-solving solution, and measures to Raymond the textile industry. The project includes reviews abstract of Raymond textile plant. It also includes energy savings and cost information when available and puts risk analysis to find a solution regarding account, production solution and implementing. First, this project gives a brief overview of the textile industry, with an explanation of major textile processes. An analysis of the type and the share of energy used in different textile processes is also included in the project. Subsequently, energy-efficiency improvement opportunities available within some of the major textile sub-sectors are given with a brief explanation of each measure. It concludes energy efficiency, improvement and the use of renewable energy in it.

Scope of the project:

A company commitment to follow this policy is at the core of Raymond ltd. company energy management system (EMS). Chindwara plant successfully implemented an energy management system that meets all requirements of ISO 50001. The accomplishment of this scope is more using automatic energy resources, reduced rising income for product and control fuel of prerequisites.

The goal of the project:

Energy-saving goals are set by management and monitored monthly. Energy performance indicators are reviewed annually. Employees are encouraged to submit energy-saving ideas.

The main goal of company energy-saving and implementing new technology in a plant with reduced cost and replacement LED light, installing VFDs and installing solar energy to use in the electric motor in a plant.

Process:

Managing energy consumption:

• Steam energy use Raymond plant around 67334 MT its almost 37.01%
• Electricity 5457527 kwh is 38.90%
• The coal used in 9848 MT around 28.68%

It this scheme the plant was given the target to reduce its consumption by 4% by employing energy saving/conservation measures in its 1st cycle i.e. during April 2016-March 2017.

(A) Electrical saving by conversion of chiller plant into normal humidification plant of spinning and weaving Dept.

Description of the energy conservation measure: By restructuring and reengineering, Unit has converted the Chiller plant into normal humidification plant. In this project, Unit removed chiller unit and install bigger supply fans to fulfill the process requirement.

Total investment – 70,315.00 USD

Total Saving – 10,997.27 USD

             Payback - 6.4 Years

(B)   Coal saving in the boiler by the installation of effimax system

Description of the energy conservation measure: By the installation of effimax system, unit monitor and control the excess air and fuel consumption in the furnace.

effimax system continuously monitor the furnace draft and coal consumption, accordingly controls the ID fan, FD fan, and Coal feeder. As a resultant, a significant amount of coal and electrical savings are achieved.

Total investment = 8437.80 USD

             Total Saving = 3965.66 USD

(C)   Electrical saving by controlling of suction fan in gill box machine

Description of the energy conservation measure: Timer has been installed for

Šsuction fan of gill box machines. By the installation of a timer, unit stop suction fan

motor, during ideal condition of machines.

Total investment = 239.065 USD

Total Saving = 1085.80 USD

             Payback = 0.2 Years

(D)   Electrical saving by the installation of VFDs in fans in humidification plant

Description of the energy conservation measure: VFDs in Supply & Return Fan

has been installed for 13 numbers of Humidification Plant. Unit monitored and reduced Motor RPM as per the weather condition. It is effective during the winter season.

Total investment = 35156.00 USD

Total Saving = 34490.00 USD

             Payback = 0.5 Years

Saving:

• company that have been implemented for energy conservation in USD

Sr.no	Implement point	The annual saving in $USD
1	Use of fuel additive in coal in boiler and thermic fluid heaters	113,696.70
2	Power saving in compressor by less use of an inefficient old compressor	196000.19
3	Thermal insulation repairing work	59222.24
4	Condensate Recovery of Steaming m/c in Spinning	12775.26
5	Changeover of Electrical Heater to Steam Heater in RF Dryer of Dyeing	6122.13
6	Saving due to Improvement in ETP aeration system	23,488.99
7	Replacement of 36-watt fluorescent tube rod by LED 16W/18W/15W tube in plant lighting. (Total 11500 No’s) and street light replacement 150 W by 45 W LED (total 45 no’s)	112,590.97

Many activities were undertaken to improve the energy performance of the plant, which includes replacement of old inefficient motors by IE2 class high efficiency motors along with VFD’s and LED light installation which gave a significant improvement in energy consumption. The project a detailed action plan consisting of responsibilities and time frame was formulated and accordingly steps were taken for implementation. For measuring the performance, a statistical tool called regression was used since it considered all the variables affecting the energy use and simultaneously assessed the effect of change in energy consumption.

CONCLUSION:

This knowledge provides information on energy-efficiency techniques and measures. The information includes energy saving and cost information when available, process of textile plant from around the Raymond. Guidelines for several steps provide the savings and returns duration found under different conditions. Always, the reader should keep in mind that the values ​​presented in this things are given as knowledge. Real costs and energy savings will change for the action based on the plant's arrangement and size, plant location, plant performance characteristics, production and product characteristics, raw materials and energy supply, and many other factors. For example, for a few energy-efficiency steps, a significant portion of the labour cost. Thus, the price of these developed and developing process can change significantly. Therefore, for all the energy-efficient solutions presented in this manual, individual plants should do more research on the economics of action, and to evaluate the probability of measuring the probability of measurement, their unique manufacturing system should proceed to the usefulness in textile industry