Efficient Uses of Steam Energy in Textiles

to Reduce Cost & Improve Productivity

2nd International Conference on Textile & Apparel, ICTA-2012

What We Do?
o Forbes

Marshall is an ISO 9001 company specializing in the Field of Steam Engineering & Control Instrumentation o We are working with steam for last 106 years and have our manufacturing facility in India and others in joint venture with Spirax Sarco, ARCA, Krohne, Codel & Vynce. o We manufacture Steam Boiler (NG/Diesel/Solid fuel fired), Exhaust Gas Boiler and almost all the steam system accessories.

Energy Audit
o Forbes Marshall has an Energy Audit division having expertise in
specific fields.

oForbes Marshall has conducted over 100 detailed energy audits across
the industry covering each and every process including dyeing units, washing units, denim plants etc.

o In each of our audits we identified the opportunity for savings ranging

from 20% to 30%. o Successful implementation of our audit recommendations of these plants has yielded significant improvements in Specific Fuel Consumption (SFC).

Why Steam?
o Fuel used for generating steam accounts for about 50% of total utility cost. o Scarcity of Natural Gas, increase in cost of fuel and hence the steam costs oEffective steam management plays a role in Fuel Savings - which can be leveraged for cost competitiveness . Reducing fuel cost is the only route to cut costs substantially. Product Quality Maintaining proper steam parameters ensures product

quality, e.g. uniform colour, print, brightness etc.

Productivity -Improving batch timings on equipment.

Benchmarking where do we stand ?

Forbes Marshall studies of over 60

textile plants reveal differences in fuel consumption within the industry. 39% difference in Specific Fuel Consumption (SFC) between the best and average plants. The worst plant consumes more

than 3 times the amount of fuel as

compared to the best plant.

Why is the best plant the best ?

Differences in Specific Fuel Consumption (SFC) across plants on account of: Efficient steam generation Optimized steam distribution & utilization Recovering condensate & flash steam Proper steam trapping

Comparative Study
Capacity Ideal Steam Consumption with (Kg) Right Steam and condensate loop (Without Heat Recovery/With Heat Recovery* (Kg/Batch) Light 250 400 600 750 461/281 660/460 863/563 Medium 559/379 711/511 1227/927 Dark 641/461 770/570 1698/1398 Actual Steam consumption (Kg/Batch) Required Actual Steam Steam Pressure Pressure (Barg) (Barg) Batch time (mins) Max Gradient (C/min)

Light Medium 527 782 907 660 839 1326

Dark 769 890 1950 3.5 3.5 3.5 6-7 6-7 6-7 400-450 450-500 500-550 5 5 5

1358/758

1817/1217 1922/1322 1585

1980

2160

3.5

6-7

550-650

1500

2227/1377 2490/1640 2769/1919 2531

2982

3187

3.5

6-7

650-700

Common issues found because of not adopting right steam engineering practices Not getting right pressure & temperature in the m/c Batch time goes high and product quality hampered Proper steam trapping is not in practice Running boiler at lower pressure Not using PRV before Process machine Not using temperature control Many of the time traps are bypassed Steam distribution system is not proper Steam mains are oversized or undersized Traps and valves leakage Insulation of Steam & Condensate line is not proper Not recovering condensate & flash steam Feed water temperature is ambient Boiler blowdown is manual

Valve Leakage
A 1/8 inch hole in
steam main can waste 15 tons of coal or 9 tons of fuel oil per year.

A leaking 25 NB Thermodynamic Trap on a 7 bar line will lose steam at the rate of 18 kg/hr. This translates to a loss of more than 150 Tons of steam annually.

Steam is venting to the atmosphere

No Steam Trap / Group Trapping in Vertical Cylinder Dryer

General Practice in Vertical Dryers

4 bar(g)

Over heated + excess dried cloth

Group trapping

Recommended Hookup Vertical Dryers

Existing Hookup Soft Flow

Recommended Hookup

Typical Steam Circuit:

Steam Space Heating System Condensate Steam Process Vessel Vat

Pan

Pan

Make-up Water Steam Feed Tank Condensate

Boiler

Feed Pump

The Steam and Condensate Loop

Distribution losses 5-7% 85%

100% Input

Boiler

Process

60% Process use

Boiler losses 13 - 15%

20% Condensate

So, for 1 Ton steam for process, fuel used equal to 1.67 Ton

Steam use in process 60% Different losses 40%

Steam Generation
Two things are directly effect boiler steam generation
- Boiler operating pressure & Feed water temperature

Poor boiler efficiency due to-

Fluctuating loads improper loading on the boiler which can be addressed by

proper boiler selection, capacity, burner turndown, etc.

Absence of diagnostics to take corrective action same can be addressed by

steam and oil flow metering, stack monitoring with boiler load management and online efficiency check. Manual Blow down - because of over blow down losses of money and less blow down increases the risk of boiler life.

Cost of a Boiler Oil/Gas fired

Steam to Fuel Ratio

Losses
Stack Enthalpy Un Burnt

Draft Steam Flow Fuel Flow Burner

Boiler

Blow down

Air

Radiation

BOILER HOUSE

What affects Fuel Bill?

Excess Air %

Feed Water Temperature

Stack temperature Un burnt losses

Number of On-Offs
Scaling on tubes Soot Deposition Blow down TDS Moisture in Fuel

What to Monitor inside Boiler House ?

1. Steam Flow

2. Steam Pressure
3. Fuel Flow 4. S: F ratio 5. Stack Temp 6. % O2 in Flue gas 7. Feed Water Temp 8. Blow down TDS 9. Furnace Pressure

Factuals
Deviation in 2% oxygen Results in 1.5 % Excess Fuel Consumption
10 % Excess Blowdown will amount to

2 % Excess Fuel Consumption

Boiler Efficiency Monitoring System

Boiler Efficiency
Losses
Stack Enthalpy Un Burnt

In Direct Efficiency Fuel Flow

100 - {
Burner

Draft

+ +

Steam Flow

Boiler

Blow down

+
Air Radiation

Conclusion
Fuel Scope for savings (%)

Gas
Liquid Solid

11.2 %
11.8 % 17.1 %

No Matter which fuel type you look at, the scope of savings is 10 % to 15 % at least. No boiler is an exception

Steam Distribution
High distribution loss across plants on account of o Improper line sizing
o Improper insulation o Improper line routing & condensate removal from steam lines

These losses can be addressed by o Proper design of the distribution network, i.e.; proper line sizing without extra
provisions for expansions o Proper insulation and efficiency checking mechanism o Proper condensate removal from steam lines o Diagnostics pressure and temperature gauges, steam flow meters, etc.

Distribute Steam at High Pressure

This will have the following advantages:
Smaller bore steam pipes needed and therefore less heat (energy) loss due to the smaller surface area.
Lower capital cost of steam mains, both materials such as pipes, flanges and support work and labour. Lower capital cost of insulation (lagging). The boiler can be operated at the higher pressure corresponding to its optimum operating condition, thereby operating more efficiently. The thermal storage capacity of the boiler is increased, helping it to cope more efficiently with fluctuating loads, and a reduced risk of priming and carryover

Pipe Sizing
Greater Cost Greater Heat Loss Greater Volume of Condensate Formed

Lower Pressure to Steam Users Not Enough Volume of Steam Water Hammer and Erosion

Waterhammer
Sagging Main

Condensate

Slug of water from condensate

Vibration and noise caused by waterhammer

Relaying to Higher Level

Fall 1/250

Steam

30 - 50m Drain Points

Relay to high level

Steam Flow Flow

Proper Condensate Drain

Steam Flow

Correct

Condensate

Cross Section

Pocket 25/30m Steam Trap Set

Steam Flow

Incorrect
Steam Trap Set

Cross Section

Branch Connections

Steam

Steam

Condensate

Incorrect

Correct

Drainage of Condensate from Steam Line

Steam Flow

Separator

Importance of Moisture Separator

Fig. Temperature profile across a heat exchange surface

Steam Utilization
Steam Trapping o In most plants, trap selection is an issue on heating
applications. o Group trapping on equipment also needs to be addressed. o Across textile plant audits and surveys we have conducted we find that only 50% of the installed traps are OK.

TD Traps are used in Process, it should be float trap

Disadvantages of TD: -Intermittent discharge. -Condensates not removed properly, get water logged. -Increase steam

consumption by 8~10%
-Increase process time By 25~30%

Ball Float Trap: Ensures proper removal of condensate from the process as soon as it forms. Recommended for process application.

Condensate & Flash Steam Recovery

o Huge gap between quantum of condensate being recovered

and potential for recovery observed across all plants.
o Across many plants, boiler feed water temperature is ambient and condensate is being drained. o In plants where condensate is recovered, it is doing using an electrical pump leading to loss of useful heat.

o Flash steam is normally not recovered and is vented. Flash

steam can be recovered and used for feed water heating.

* This calculation is made for diesel fired boiler.

Similarly it can be done for gas fired boiler.

oCondensate water contains 20% energy of steam. Returning condensate improves the feed water temperature and thus lowers fuel bill. o Returning condensate to feed water tank cuts the makeup water requirements. o The condensate returned does not need to undergo water treatment and thus saving treatment cost. o It has no TDS. It reduces the requirement of blowdown thereby

curtailing blowdown losses.

o Reduce the cost for oxygen scavenging chemicals, since the improved temperature will reduce the amount of dissolve oxygen almost 75%.

o Higher feed water temperature by recovering condensate

increases the boiler output with reduced fuel consumption.

o Recovering flash steam is as important as recovering condensate water. Flash steam contains 50% energy of the total

recovered condensate, although it may be 10~15% in mass.

[Please Note: Holding condensate in collection tanks reduces the condensate temperature via radiation losses. Condensate should be returned as soon as it formed. ]

Benefits of Condensate Recovery:

Energy Content in Dye Liquor

Not considering losses the Process Heat Recovery in Dyeing m/c

Energy Content

45 %

Dye Bath Liquor Cooling Water 15 %

Benefits of Dye Liquor Heat Recovery

o Recover heat from dye liquor 60~80 deg C from the dyeing machine. Savings up to 15% in steam used for hot water preparation. o Pre-heats process water to the dyeing machine. 1-2 extra batches per week possible. o Facilities low temperature discharge to ETP. Helpful for effluent treatment. o Eliminates pressure fluctuation of boiler.

Dye Liquor Heat Recovery System

Enconomy opportunities
Trap Management Selection of right Trap Bypass Leakage Stop Leakages Insulation Condensate Recovery Flash Steam Recovery Stop Blowdown Losses Feedwater tank Management

Stop Waste (12-15%)

Encon opportunities
Steam Flowmetering Dye Liquore Heat Recovery Efficiency Optimisation Liquor ratio control Steam Pressure Control Temperature Control Instant Hot water supply Dryness of Steam Waste Management Capacity Utilisation

Optimization ( 8-10%)

Encon Opportunities
Boiler Efficiency Monitoring Waste Heat Recovery Boiler from Generator Thermic Fluid GeneratorEfficiency % optimisation Hot water from DG set Jacket

Heat Recovery (7-8%)

Optimization

Waste Management

Our recommendations which included

o Optimized steam generation o Improved steam distribution system

o Proper selection and sizing of steam traps

o Better management of the process like installing temprature & pressure controls

o Utilizing waste heat recovery

o Recovering condensate with flash steam to improve the boiler performance

Forbes Marshall has a Consultancy Division worked for the project design and consultancy for steam, water & air distribution system to make the industry energy efficient and sustainable. Forbes Marshall has done Consultancy in many industries of Bangladesh. Few of them are, Hameem Denim, DBL, Ecotex, GMS composite, Graphics Textils, etc.

Copyright Forbes Marshall, 2006-07

One of Many Successes in Bangladesh!!

Industry Location Steam Usage Fuel

Knit Concern

Cutting

Narayangong Down Fabric Dyeing, Finishing & Garments Gas

Costs

Before Energy Audit -They have a requirement of 3~4 TPH boiler - Their machine was starving for steam After Energy Audit & Implementing Recommendations

Till now they have no shortage of steam and no requirement of steam boiler
Reason found : Wastage and leakage of steam in different points Condensate was not recovered Boiler was running under pressure Too much blowdown losses Live steam wastages from garments section.
Copyright Forbes Marshall, 2006-07

One of Many Successes!

Industry Location Steam Usage Fuel Textile Processing Unit Cutting Madhya Pradesh Down In Process eqpt Stenters, Back filling M/cs, Calendar M/c etc Wood

Costs

The objective - Improve SPFC from 0.33 kgs wood/mt cloth (Rs 0.66/ mt cloth). Energy conservation recommendations implemented by customer -optimized fuel management sizing. -Optimized steam generation -undertook better management of process like temp control. -optimized waste heat recovery -reduced losses on account of inappropriate / in-operational trapping
The Results?
Kg/Meter cloth
0.34 0.33 0.68 0.66

0.31 0.3 0.29 0.28 0.27

0.62 0.6 0.58 0.56 0.54 Pre Audit Post Implementation

Copyright Forbes Marshall, 2006-07

Rs/ Meter cloth

The SPFC came down to 0.28 Kg Wood/ Mt Cloth (Rs0.58/MtCloth)!!

0.32

0.64

One of Many Successes!

Industry Location Steam Usage Fuel Textile Processing Unit Gujarat Yarn Dyeing M/cs HSD

Cutting
Down

Costs

The objective Reduce Fuel Consumption Energy conservation recommendations implemented by customer -Optimized steam generation -Reduced losses in steam distribution circuit -undertook better management of process like temp control. -optimized waste heat recovery dye liquor, condensate & flash recovery. -reduced losses on account of inappropriate / in-operational trapping
The Results? Before Fuel Consumption (lts/day) Costs (Rs/day) 1,150 17,250 After Audit 820 9,020

Customer Saves Rs 30 Lakhs/year!!

One of Many Successes!

Cutting
Down

Costs

One of Many Successes!

Cutting
Down

Costs

Fuel prices would

continue to spiral
upwards. & so would your losses!

The longer you wait..

The more your losses accumulate!

Find out where you stand!!! Get a free scoping study done by FM Experts

Bangladesh Office Address:

3rd Floor, Rupsha Tower, Kamal Ataturk Avenue,

Road -17, Banani C/A, Dhaka. Email: bangladesh@forbesmarshall.com Website: www.forbesmarshall.com

Thank You