2 nd WORKSHOP ON BEST PRACTICES IN ENERGY EFFICIENCY IN TEXTILE - - PowerPoint PPT Presentation

Presentation By,

• Mr. G.D. Panchal (CMD of Draft Air(INDIA) PVT. Ltd. & Chicago

Blower (INDIA) PVT. Ltd.) on the subject of

“ENERGY EFFICIENCY IN AIR-CONDITIONING & WASTE COLLECTION SYSTEM IN TEXTILE INDUSTRIES” .

2nd WORKSHOP ON

“BEST PRACTICES IN ENERGY EFFICIENCY IN TEXTILE SECTOR”

Energy Saving Up to 25% in Textile Air Conditioning

 Economical System Design  Selection of Economical Equipments to match the

requirement of Efficient System Design

 Effective Distribution of Supply and Return Air with

Appropriate balancing

 E-Communication with the Variable Frequency Drive.

Efficient System Design

1)

Location Of Plant

2)

Damper Location

A.

Fresh Air-Damper

B.

Exhaust Air-Damper

C.

Return Air Damper

3)

Location of Fan & Fan Accessories

A.

“Bell Shaped” Inlet Cones

B.

Outlet Cone at Fan Discharge side.

C.

Extra Precautions should be considered such as Distance between inlet/outlet of FAN and the Wall

Fan Performance Respective to the Wall Distance

Economical Selection of Equipments

1)

Supply Air Fans

2)

Return Air Fans

3)

Rotary Air Filters

4)

Pumps And Piping

a)

2 Bank System

b)

2 Pump Each of 50% Capacity

c)

Saving in 5% to 10% in energy cost

d)

Saving is possible with both Manual and Automatic Operation of the Pumps.

Effective Distribution of Supply and Return Air with Appropriate balancing

• Distribution of Air According to Heat Concentration.
• Apposite Design of SA Duct and Return Air trenches.
• Flow of Air - Laminar
• Velocity of Air- Uniform & Constant
• Direction of Air- From Diffuser to Grilles
• Uniform Velocity Through Diffuser & Uniform Suction through

Grilles.

Suitable Provision for Distribution of Air helps in

 Efficient balancing of Supply Air and Return Air in the

Department.

 Consistent and Uniform Air Quantity.  No Hot Pockets in the Department.  Enhancement in Quality of YARN and FABRIC.  Removal of Floating Fluff in Department.

CAUTION

 Apart from properly Designed Supply Air Duct enough

attention should be given to Return Air Trench.

 Normally Velocity through grilles near the return air system is more than the designed

velocity compared to the grilles which are located away.

 This variation in velocity vary according to department length, number of ducts and size

• f the grilles.

 Variation in velocity causes hot pockets , floating fluff, turbulence of air and severe

imbalance of system

 Enough Attention Shall be given to Overcome

such Problem by,

Replacement of Motor with Higher HP Motor. Changing Blade Angles to enhance the capacity.

This results ultimately in more POWER

CONSUMPTION.

Supply Air & Return Air System normally installed for Simplex

Perfectly Balanced Supply & Return Air System for Simplex

Unbalanced Air Distribution

Resultant of Unbalanced Air Distribution

Proper Balanced System

E-Communication with the Variable Frequency Drive.  Automation helps in maintaining the Humidity and

Temperature at Constant Level.

 Proper Mixture of Supply Air and Return Air  Set points can be easily changed as per Requirement of

Different Department.

 Control of Speed of the fans through VFDs.  Control of flow of water in the spray.  CMS(Central Monitoring System) provides Current Data of Different

Departments and also has Facility to change the Conditions.

 System can be also monitored and controlled from Long Distance

with help of Net Connectivity.

Need for Variable Frequency Drives

• Normally Plants are designed for

1.

Peak Summer Conditions

2.

Maximum Load Factor of Machines

• But there are situations when:-

1.

Atmospheric conditions vary day and night & season to season

2.

Machines are working at varying load factor.

Thus requirement of air circulation reduces, And here we need VFD on fans.

Effect of Varied FAN-Speed in System

 FAN LAWS SAYS:-

• Air Volume a Speed
• Pressure a (Speed)2
• Power a (Speed)3

If Speed reduces by 10%

Then , Air Volume reduces by 10% Pressure reduces by 19% Power reduces by 27%

If Speed increases by 10%

Then , Air Volume increases by 10% Pressure increases by 21% Power increases by 33%

Advantages of Automation and VFDs

 Savings of power 5-10% when only Automation is installed with 2

Pumps System.

 25-30% Minimum power savings if Variable Frequency Drives (VFDs)

are also installed with Automation.

 Recovery of Cost of VFD is very Reliable ,it can be achieved within 15 –

24 months depending upon geographical location of the site, varying load conditions and Power Cost.

SCHEMATIC DIA. OF GENERAL TEXTILE WASTE COLLECTION SYSTEM

FAN DESIGNED AT 2250 PA

CLEAN CONDITION

(MINIMUM)

CHOCK CONDITION

(MAXIMUM) Negative Pressure required by M/C Supplier (-600Pa Minimum M/C

• perating Cond.)
• 600Pa
• 800Pa

Duct Loss

• 600Pa
• 600Pa

Primary (Disc) Filter losses

• 50Pa
• 150Pa

Secondary(Rotary) Filter Losses

• 75Pa
• 250Pa

Exhaust Losses

• 300Pa
• 300Pa

TOTAL

• 1625Pa
• 2100Pa
• 2250(Considered for final design

including unforeseen losses; Air & Duct losses)

PERFORMANCE OF FAN

PERFORMANCE OF SOLO FAN UNDER DIFFERENT DESIGN LOAD

MAINTENANCE OF PLANT

 This is the Most Important Aspect results, in saving lots of

Power.

 Scheduled Cleaning of Eliminators, Intake Louvers and

Nozzles prevents them from chocking.

 Changing the Past life-timed Parts ensures the stability of

plant and Increase the Life-Time of Plant.

 This will ensure Designed Air Circulation in Department

and desired RH & Temperature is continuously maintained.

CREATING JUST THE RIGHT ATMOSPHERE - ALWAYS