LOW GRADE WHU POTENTIAL-

TEXTILE SECTOR
Partnership to Advance Clean Energy-Deployment (PACE-D)
Technical Assistance Program

R Rajmohan 12-Aug-14
CONTENTS

• Process Flow
• Sources of Low Grade Waste Heat
• Overall Potential
• WHU Solutions
• Case Studies
Textile Processing : Illustrative for Cotton Prints
Process Utilities
Boiler

Thermopac

Air
compressors

Source: Cluster Manual Pali Textile

Cluster; BEE
Textile Processing : Pali Textile cluster- Quick overview

Sl No Item Target Efficiency

1 Sources of Energy Electricity from Grid & Pet Coke

2 Energy Use pattern – Pet 5 to 7 TPD (Power process)
Coke 1 to 1.5 TPD (Small Units)

3 Energy Use pattern- Power Process: 3000 kWh/Day

Electricity Only printing: 160-500 kWh/Day
4 Specific energy Electricity: 1.2 kWh/Kg
consumption ( Processing Thermal: 15000 Kcals/Kg
of polyester & Printing)

Source: Cluster Manual Pali Textile

Cluster; BEE
 Sources of Waste Heat

Boiler Jigger Drying Stente Dyeing Stretc Singei Jigger Drying

r hing ng
Low Grade WH: Overall Potential
Effluents Jiggering & Swing Steam
Quantity: 3000 Kg/Cycle Reject condensate: 120 Kg/Hr
Temperature: 70 Deg C Temperature: 70 Deg C
WHR potential: 120000 Kcals/Cycle WHR potential: 6300 Kcals/Cycle

Dyeing @ 140
Stretching @
Deg C
120 Deg C
Reject effluent:
WHU- Overall potential Reject Effluent:
5000 Kg/Hr
0.323 Kg of Fuel/Kg of Cloth 123 Kg/Hr
Temperature: 100
Deg C Annual fuel savings: 93 MT/Year Temperature: 100
WHR potential: Cost savings: 11.2 Lac Rs/Year Deg C
408000 WHR potential:
Kcals/Cycle 1230 Kcals/Cycle

Drying & Jiggering Steam Drying & Jiggering water

Reject Effluent: 200 Kg/Hr Reject condensate: 3500 Kg/Hr
Temperature: 70 Deg C Temperature: 70 Deg C
WHR potential: 12000 Kcals/Cycle WHR potential: 210000 Kcals/Cycle
Mill producing 37 Kg of cloth/Hr
 Low Grade WHU Technologies: Waste heat recovery
from Boiler Flue gases - Economizer
T2 = 50
Deg.C

E
Flue Gas C To Chimney
Boiler
200 Deg.C O 150
Deg.C

T1= 30
Deg.C

Feed water Pump

• 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
 Low Grade WHU Technologies: Waste heat recovery
from Boiler/Thermopac Flue gases – Air Preheater
T2 = 80
Deg.C

A
Boiler/ Flue Gas P
Thermo pac 200 Deg.C 150 Deg.C
H

Combustion T1= 30 Deg.C

air

FD Fan

• 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)
Feed
Water
Tank

Flue
Gas S& T
Boiler
HE To Chimney

Water
Pump

• Waste heat recovery device Feed water

Pump
• 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
 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
Savings by Installing Waste heat recovery System in Boiler
Item Unit Value
As Is To be
Flue gas temperature Deg C 204 180
GCV of fuel Kcals/Kg 8000 8000
Fuel used MT/Year 1260 1210
Savings in fuel MT/Year 50
Cost of Fuel Rs/MT 12000 12000
Savings n Energy cost Rs/Year 600000
Investment Rs 300000
Simple Payback period Year 0.5
CASE STUDY 2 : Waste heat recovery system in Thermopac
Savings by Installing Waste heat recovery System in Thermopac
Item Unit Value
As Is To be
Flue gas temperature Deg C 250 180
GCV of fuel Kcals/Kg 8000 8000
Fuel used MT/Year 1800 1710
Savings in fuel MT/Year 90
Cost of Fuel Rs/MT 12000 12000
Savings n Energy cost Rs/Year 1080000
Investment Rs 500000
Simple Payback period Year 0.5
CASE STUDY 3 : Waste heat recovery –Boiler Blowdown
Savings from Boiler blowdown heat recovery
Item Unit Value
As Is To be
Quantity of water per blowdown
Lit 200 200
No of blowdown per day Nos 5 5
Total blowdown quantity Lit/Day 1000 1000
Total heat recovery from blowdown
Kcals/Day 80000 80000
Savings in fuel MT/Yr 3.4
Savings n Energy cost Rs/Year 40800
Investment Rs 50000
Simple Payback period Year 1.2
CASE STUDY 4 : Waste heat recovery- Jet Dyeing Machine
Savings from Heat recovery- Jet Dyeing Machine
Item Unit Value
As Is To be
No of Jet Dyeing Machine Nos 3 3
Steam consumption/Hr Kg/Hr 150 150
Flash steam recovery potential
Kcals/Hr 28800
Savings in fuel MT/Yr 29.5
Savings n Energy cost Rs/Year 354000
Investment Rs 200000
Simple Payback period Year 0.6
CASE STUDY 5 : PHE – Heat Recovery from Jet
Dyeing Machine (Sameer Synthetics)

Temp. of water drained : 85oC

Proposal : 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