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Energy conservation in textile industries & savings
By :   Aravin Prince
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Ultrasonic Assisted Wet Processing


Ultrasonic assisted process is an alternative to conventional high temperature processing of the textile materials. Ultrasound equipment installed in the existing machines offer improved performance in fabric preparation and dyeing without impairing the properties of the processed materials. The influence of ultrasound intensifies the mass transfer in the wet processing of textile materials. The advantages of ultrasonic in textile wet processing include energy saving by reduced processing temperature, time and lower consumptions of auxiliary chemicals and further processing enhancement by control of overall costs. Therefore, the areas that demand higher energy consumption can be benefited using ultrasound techniques.


Foam Technology


The application of foam processing leads to considerable savings in the energy required for heating, drying, thermo-fixing, and steaming and so on because the water content is very low. The foam processes bring down the liquor ratios required for pretreatment, dyeing and finishing by producing uniform foam with the required characteristics in terms of viscosity, stability, and blow ratio. De-sizing, bleaching and finishing as well as fluorescent brightening of goods can be done using a foam technique. It offers potential savings in materials and energy.


Energy Conservation through Software Approach


NITRA has developed a user friendly approach which performs energy balance on any machine in a textile mill, stores the data along with information on the actual cost and theoretical cost of the performed operation along with the gradation of quality obtained. Records stored by this operation can be recalled later to review weekly/monthly/yearly performance of machine. The software is also helpful in comparing the energy demands between machines processing the same production and shade. This can help in the selection of a machine required for a particular quality where the cost benefit will be more.


Non-Conventional Sources of Energy


The different alternative renewable sources of energy are biomass, geothermal energy, tidal energy, wind energy and solar energy. Out of these energy sources, solar energy is abundant and is inexhaustible, in fact, fossil fuel, viz. coal, oil and natural gas are their origin to these energy sources. India's geographical location favours unlimited and uninterrupted supply of solar energy and hence it must be effectively utilized. Solar energy is widely utilized in the heating up of water. Solar water heaters are available that are used to save thermal energy to a great extent. The bagass and biogas is used as fuel in the boilers which is readily available. The gas can be produced and consumed at the place of production and hence cost of transportation of raw material and gaseous product is eliminated. The technology is simple and easy to operate, with virtually very little maintenance cost. There will not be any problem of air pollution. In short, nothing is wasted and there is no effluent.


Table-I


1 Processing

65%

2 Sizing & Size mixing

15%

3 Humidification in spinning & weaving

10%

4 Unaccountable due to line losses, leaks etc. & engineering

10%

Total

100%


Sr. No.

Dyeing process

Steam consumption in Kg / Kg of fabric

1

Dyeing in jigger or winches

3.5

2

Dyeing in H.T.H.P. dyeing machine

5

3

Pad - dry steam dyeing

8

4

Pad - dry cure/thermo sole dyeing

5


 

1 2 3 4 5 6  ]    

 

 
 
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