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Efficient Uses of Steam Energy in Textiles
to Reduce Cost & Improve Productivity
2nd International Conference on Textile & Apparel, ICTA-2012
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What We Do?
oForbes Marshall is an ISO 9001 company specializing in
the Field ofSteam Engineering & Control Instrumentation
o We are working with steam for last 106 years and haveour manufacturing facility in India and others in joint
venture with Spirax Sarco, ARCA, Krohne, Codel & Vynce.
o We manufacture Steam Boiler (NG/Diesel/Solid fuelfired), Exhaust Gas Boiler and almost all the steam system
accessories.
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Energy Audit
oForbes 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).
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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 Saving s- which can be leveraged for cost competitiveness . Reducing
fuel cost is the only route to cut costs substantially.
Produ ct Qual i ty
Maintaining proper steam parameters ensures product
quality, e.g. uniform colour, print, brightness etc.
Product iv i ty-Improving batch timings on equipment.
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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.
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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
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Comparative Study
Capacity
(Kg)
Ideal Steam Consumption with
Right Steam and condensate loop
(Without Heat Recovery/With
Heat Recovery* (Kg/Batch)
Actual Steam
consumption
(Kg/Batch)
Required
Steam
Pressure
(Barg)
Actual
Steam
Pressure
(Barg)
Batch
time
(mins)
Max
Gradient
(C/min)
Light Medium Dark Light Medium Dark
250 461/281 559/379 641/461 527 660 769 3.5 6-7 400-450 5
400 660/460 711/511 770/570 782 839 890 3.5 6-7 450-500 5
600 863/563 1227/927 1698/1398 907 1326 1950 3.5 6-7 500-550 5
750 1358/758 1817/1217 1922/1322 1585 1980 2160 3.5 6-7 550-650 5
1500 2227/1377 2490/1640 2769/1919 2531 2982 3187 3.5 6-7 650-700 5
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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
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A 1/8 inch hole in
steam main can waste
15 tons of coal or 9
tons of fuel oil per
year.
Valve
Leakage
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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.
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Steam is venting
to the
atmosphere
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No Steam Trap / Group Trapping in Vertical Cylinder Dryer
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General Practice in Vertical Dryers
Group trapping
4 bar(g)
Overheated
+excessdriedcloth
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Recommended Hookup Vertical Dryers
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Existing Hookup Soft Flow
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Recommended Hookup
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Typical Steam Circuit:
Pan Pan
Boiler
Feed
Pump
Feed
Tank
Make-up Water
Vat
Condensate
Condensate
Steam
Steam
Steam Process
Vessel
Space
Heating
System
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The Steam and Condensate Loop
Boiler100% Input Process
Distribution losses 5-7%
85%
Boiler losses 13 - 15% 20% Condensate
60% Process
use
So, for 1 Ton steam for process, fuel used equal to 1.67 Ton
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Steam use in process 60%
Different losses 40%
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Steam Generation
Two things are directly effect boiler steam generation
- Boiler operating pressure & Feed water temperature
Poor boiler efficiency due to-
Fluctuat ing loads improper loading on the boiler which can be addressed by
proper boiler selection, capacity, burner turndown, etc.
Abs ence of diagnost ics to take correct ive act ion 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.
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Cost of a Boiler
Oil/Gas fired
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Steam to Fuel Ratio
Radiation
FuelFlow
Burner
LossesStack
EnthalpyUn Burnt
Boiler
Draft
Blow down
SteamFlow
Air
BOILER HOUSE
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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
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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
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Deviation in 2% oxygen Results in 1.5
% Excess Fuel Consumption 10 % Excess Blowdown will amount to
2 % Excess Fuel Consumption
Factuals
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Boiler Efficiency
Monitoring System
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Radiation
FuelFlow
Burner Boiler
Draft
Blow down
SteamFlow
Air
In DirectEfficiency
=
100 - { + }+
+
LossesStack
EnthalpyUn Burnt
Boiler Efficiency
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Fuel Scope forsavings (%)
Gas 11.2 %
Liquid 11.8 %
Solid 17.1 %
No Matter which fuel type you look at, thescope of savings is 10 % to 15 % at least.
No boiler is an exception
Conclusion
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Steam Distribution
High distribution loss across plants on account of -
oImproper line sizing
o Improper insulation
o Improper line routing & condensate removal from steam lines
These losses can be addressed by -
oProper 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.
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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 aspipes, 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, therebyoperating 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
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Pipe Sizing
Greater Cost Greater Heat Loss
Greater Volume of CondensateFormed
Lower Pressure to Steam Users
Not Enough Volume of Steam Water Hammer and Erosion
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Waterhammer
Sagging Main
Slug of water fromcondensateVibration and
noise caused by
waterhammer
Condensate
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Relaying to Higher Level
Steam
Relayto high
level
Drain Points
30 - 50m
Fall 1/250
Steam Flow Flow
Proper Condensate Drain
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Proper Condensate Drain
Condensate
PocketSteam Trap Set25/30m
Cross
Section
Cross Section
Steam Trap Set
Steam Flow
Steam Flow
Correct
Incorrect
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Branch Connections
CorrectIncorrect
Steam Steam
Condensate
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Drainage of Condensate from Steam Line
Steam Flow
Separator
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Fig. Temperature profile across a heat
exchange surface
Importance of Moisture Separator
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Steam Utilization
Steam Trapping -
oIn most plants, trap selection is an issue on heatingapplications.
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.
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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%
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Ball Float Trap:
Ensures proper removal of condensate from the process as soon as itforms. Recommended for process application.
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Condensate & Flash Steam Recovery
oHuge 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.
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*This calculation is made for diesel fired boiler.
Similarly it can be done for gas fired boiler.
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o
Condensate water contains 20% energy of steam. Returning condensateimproves the feed water temperature and thus lowers fuel bill.
oReturning 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.
oIt 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%.
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o Higher feed water temperature by recovering condensate
increases the boiler output with reduced fuel consumption.
oRecovering 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 co l lect ion tanks reduc es thecon densate temperature via radiat ion los ses. Condensate sho uld be
returned as soon as it formed. ]
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Benefits of Condensate Recovery:
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Energy Content in Dye Liquor
Not considering losses the Process Heat Recovery in Dyeing m/c
45 %
15 %
Dye Bath LiquorCooling Water
Energy Content
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Dye Liquor Heat Recovery
System
E t iti
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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%)
Enconomy opportunities
E t iti
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Optimization ( 8-10%)
Waste Management
Steam Flowmetering
Dye Liquore Heat Recovery
Efficiency Optimisation
Liquor ratio control
Steam Pressure Control
Temperature Control
Instant Hot water supply
Dryness of Steam
Capacity Utilisation
Encon opportunities
E O t iti
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Encon Opportunities
Boiler EfficiencyMonitoring
Waste Heat Recovery
Boiler from Generator
Thermic Fluid Generator-
Efficiency % optimisation
Hot water from DG set
JacketOptimization
Waste Management
Heat
Recovery
(7-8%)
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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
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Copyright Forbes Marshall, 2006-07
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.
One of Many Successes in Bangladesh!!
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Copyright Forbes Marshall, 2006-07
One of Many Successes in Bangladesh!!
CuttingDown
CostsIndustry Knit ConcernLocation NarayangongSteam Usage Fabric Dyeing, Finishing & GarmentsFuel Gas
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.
http://images.google.co.in/imgres?imgurl=http://www.dow.com/versene/images/textiles.jpg&imgrefurl=http://www.dow.com/versene/app/text/&h=272&w=250&sz=19&hl=en&start=1&tbnid=o6X_EFO_n3eTfM:&tbnh=113&tbnw=104&prev=/images%3Fq%3DTextiles%26svnum%3D10%26hl%3Den%26lr%3D7/27/2019 Efficient Uses of Steam Energy
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One of Many Successes!
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One of Many Successes!
CuttingDownCosts
Industry Textile Processing Unit
Location Gujarat
Steam Usage Yarn Dyeing M/cs
Fuel HSD
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?
Customer Saves Rs 30 Lakhs/year!!
Before After Audit
Fuel Consumption (lts/day) 1,150 820
Costs (Rs/day) 17,250 9,020
One of Many Successes!
http://images.google.co.in/imgres?imgurl=http://www.dow.com/versene/images/textiles.jpg&imgrefurl=http://www.dow.com/versene/app/text/&h=272&w=250&sz=19&hl=en&start=1&tbnid=o6X_EFO_n3eTfM:&tbnh=113&tbnw=104&prev=/images%3Fq%3DTextiles%26svnum%3D10%26hl%3Den%26lr%3D7/27/2019 Efficient Uses of Steam Energy
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One of Many Successes!
Cutting
DownCosts
One of Many Successes!
http://images.google.co.in/imgres?imgurl=http://www.dow.com/versene/images/textiles.jpg&imgrefurl=http://www.dow.com/versene/app/text/&h=272&w=250&sz=19&hl=en&start=1&tbnid=o6X_EFO_n3eTfM:&tbnh=113&tbnw=104&prev=/images%3Fq%3DTextiles%26svnum%3D10%26hl%3Den%26lr%3D7/27/2019 Efficient Uses of Steam Energy
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One of Many Successes!
Cutting
DownCosts
http://images.google.co.in/imgres?imgurl=http://www.dow.com/versene/images/textiles.jpg&imgrefurl=http://www.dow.com/versene/app/text/&h=272&w=250&sz=19&hl=en&start=1&tbnid=o6X_EFO_n3eTfM:&tbnh=113&tbnw=104&prev=/images%3Fq%3DTextiles%26svnum%3D10%26hl%3Den%26lr%3D7/27/2019 Efficient Uses of Steam Energy
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Find out where you stand!!!
Get a free scoping study done by FM Experts
Fuel prices would
continue to spiral
upwards. & so
would your losses!
The longer you wait..
The more your losses
accumulate!
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Bangladesh Office Address:
3rd Floor, Rupsha Tower, Kamal Ataturk Avenue,
Road -17, Banani C/A, Dhaka.
Email: [email protected]
Website: www.forbesmarshall.com
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