Energy makes a very important contribution to industries and their activities. Nowadays textile industries growth is going on increasing day by day and energy consumption is one of the biggest challenging issues in textile industry because it significantly affects on the total production cost hence as we reduce the power consumption in some extent also then it will create the good impact on production cost. So this paper describes different possibilities to conserve the energy in different departments of textile industries.
As energy is a basic factor to run any industry, but today due to increasing power cost there is necessary to conserve the energy. In any textile mill, there are numbers of processes for that processes require various types of machinery. Because of improper setting & operating parameters, improper environment and improper maintenance cause inefficient working of machines which will lead to consuming more power. By doing an energy audit and finding areas where extra power is consuming and where power we can conserve.
In textile mill to produce a yarn, the basic operations are carried out on raw material i.e. fibre like opening, cleaning & mixing in blow room, individualization & fibre to fibre mixing in carding, drawing in of fibre strand in draw frame, removal of hooks & predetermine length of fibres in comber, imparting false twist into the fibre strand in
speed frame, converting fibre strand into twisted yarn on ring frame and finally wound the yarn by removing faults on suitable package.
To perform this operation the study is carried out in spinning mill and power consumed in kWh different machines and departments is shown in the chart.
– B/R is the first department in the spinning industry where we can find many alternatives to save the energy. As objects of B/R are opening, cleaning, remove contaminations and de-dusting. If we can achieve this objects efficiently then we can reduce the excess of power which will go to consume.
As per table Following are some ways by which we can reduce excess consumption of energy. In B/R department the material come in the form of bale so for effective operation in B/R we have to check the condition of the bale like impurity level, mean length of fibre, etc. by which we can set required setting, speed of m/c parts for getting require quality with low consumption. Otherwise chances of requirement reprocessing of material due improper blow room operation.
By avoiding reprocess we can reduce much amount of power. Motors and driving elements also create influence on the power to be used and will be transferred. The particular motor should be chosen for the particular operation and no. of elements to be driven. For proper transmission of motion, driving elements plays the important role. According to positive or negative motion transmission, efficiency, the power which is to be transfer, etc. by which driving elements are used.
Proper positioning of machines i.e.the proper sequence of the machines. If it is not proper then more power will consume in the transportation of material.
Proper condition of the machine in blow room dept. and central waste collection system, the material transportation though pipe should be such a way then there is less no. of sharp turns in pipes which reduce air consumption. As air consumption reduces then power consumption also reduces.
D/F, carding and S/F
Use of maximum gearless drive, simply constructed gearing and use of belts instead of gears for D/F and S/F with individual servo motors without gears and differential gearbox are given better results regarding low consumption of energy.
For carding also use one high-performance motor with geared drive consumes more power than use of individual servo motor to drive different carding elements.
R/F is most power consuming department in textile industries. Almost 50%-60% of total power consumed in R/F
department only. From graph-1 we can say that if we reduce power consumption in R/F dept. then there is the significant change in total power consumption.
It is clear that there the direct relationship between the power and speed of ring frame machine. So by keeping the optimum speed of ring frame machine, we can save the energy. For insert, one twist spindle has to rotate ones, on a machine by keeping optimum twist level excessive consumption can be avoided. In-ring frame spindle is one of the main element. Mainly the power consumes to drive the spindle. Proper spindle alignment, lubrication and driving arrangement can save the energy. The casting used for spindle should be light weight.
OHTC which is used for suck the fly and fluff generated in ring frame. Instead of keeping continuous in motion using the facility of reverse and stop button to stop it when there is no requirement of its working.
Maintenance of machine should be done properly. Idle spindles are more than for same power consumption will get less production. Also, leakage in top arm pressure pipes and at any joints can lead to consuming more power, so any leakages are avoided in ring frame.
Driving arrangement of machine-made such a way that there is less number of excessive linkages, at the proper position from the frame of the machine and horizontal, light weight driving elements, etc.
Maintaining required Relative Humidity and Temperature in the textile industry is very important and necessary task. For this one or more humidification plants are used in industries which involves a number of motors are loaded greater than related power.
In one of the mill, power study had been conducted. The load pattern of the motor was considered as 92% and above that, it considered over loaded.
By servicing and optimizing the motors which are marked as over loaded, considerable power saving can achieve. The illustrated optimum value of the study is 4 kWh/h.
By selecting the optimum pressure we could save power. The pipes should be leakage free, for cleaning use separate compressor is advisable. The filter should be changed after the specific time period, it also prevents contamination mix with air and improves effective working of the compressor.
Other ways to reduce the energy consumption
As we know there are two types of energies renewable and non-renewable. As limited sources available and due increasing demand the cost of non-renewable energies are increasing. So the use of renewable energy sources like solar energy is convenient to use for boilers, lighting systems. Use of maximum daylight and use of LED lights instead of normal also helpful to the reduction in consumption cost.
1)A study on energy conservation in textile industry journal of the institution of engineers (India): series B march2013, volume94 by- Y. Dhayaneshwaran, L. Ashokkumar.
2) Energy conservation technological solutions for spinning by VOLTAS LIMITED (knowledgeplatform.in).
3) Important key points for energy saving inspinning mills, interviewMr. S.Raguram at janaki cotton mills.