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LOW GRADE WHU POTENTIAL- TEXTILE SECTOR

Partnership to Advance Clean Energy-Deployment (PACE-D) Technical Assistance Program. LOW GRADE WHU POTENTIAL- TEXTILE SECTOR. R Rajmohan. 12-Aug-14. CONTENTS. Process Flow Sources of Low Grade Waste Heat Overall Potential WHU Solutions Case Studies.

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LOW GRADE WHU POTENTIAL- TEXTILE SECTOR

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  1. Partnership to Advance Clean Energy-Deployment (PACE-D)Technical Assistance Program LOW GRADE WHU POTENTIAL- TEXTILE SECTOR R Rajmohan 12-Aug-14

  2. CONTENTS • Process Flow • Sources of Low Grade Waste Heat • Overall Potential • WHU Solutions • Case Studies

  3. Textile Processing : Illustrative for Cotton Prints Process Utilities Boiler Thermopac Air compressors Source: Cluster Manual Pali Textile Cluster; BEE

  4. Textile Processing : Pali Textile cluster- Quick overview Source: Cluster Manual Pali Textile Cluster; BEE

  5. Water Steam (LP) 3 bar Water Steam (LP) 3 bar Thermic fluid 210 oC Water Steam (MP) 5 bar Steam (LP) LPG flame Water Steam (LP) Steam (LP) Jigger Drying Stenter Dyeing Stretching Singeing Jigger Drying Hot effluent Vapor Condensate Flue gas Vapor Hot effluent Vapor Vapor Condensate None Hot effluent Vapor Condensate Sources of Waste Heat Fuel Steam (LP) 3 bar Boiler Flue gas Blow Down

  6. Low Grade WH: Overall Potential Effluents Quantity: 3000 Kg/Cycle Temperature: 70 Deg C WHR potential: 120000 Kcals/Cycle Jiggering & Swing Steam Reject condensate: 120 Kg/Hr Temperature: 70 Deg C WHR potential: 6300 Kcals/Cycle Dyeing @ 140 Deg C Reject effluent: 5000 Kg/Hr Temperature: 100 Deg C WHR potential: 408000 Kcals/Cycle Stretching @ 120 Deg C Reject Effluent: 123 Kg/Hr Temperature: 100 Deg C WHR potential: 1230 Kcals/Cycle WHU- Overall potential 0.323 Kg of Fuel/Kg of Cloth Annual fuel savings: 93 MT/Year Cost savings: 11.2 Lac Rs/Year Drying & Jiggering Steam Reject Effluent: 200 Kg/Hr Temperature: 70 Deg C WHR potential: 12000 Kcals/Cycle Drying & Jiggering water Reject condensate: 3500 Kg/Hr Temperature: 70 Deg C WHR potential: 210000 Kcals/Cycle Mill producing 37 Kg of cloth/Hr

  7. Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases - Economizer T2 = 50 Deg.C Boiler E C O To Chimney Flue Gas 200 Deg.C 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

  8. Low Grade WHU Technologies: Waste heat recovery from Boiler/Thermopac Flue gases – Air Preheater T2 = 80 Deg.C Boiler/ Thermo pac APH Flue Gas 200 Deg.C 150 Deg.C T1= 30 Deg.C Combustion 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

  9. Feed Water Tank Low Grade WHU Technologies: Waste heat recovery from Boiler Flue gases – Water Preheater (S&T heat exchanger) Flue Gas Boiler S& T H E To Chimney Water Pump 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 boiler feed water • Useful when the feed water flow to the boiler is not continuous

  10. 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

  11. 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

  12. 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

  13. Low Grade WHU Technologies: Heat Recovery from Hot effluents • Waste heat recovery device • Used to recover heat from process effluents

  14. 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

  15. CASE STUDY 1 : Waste heat recovery system in Boiler

  16. CASE STUDY 2 : Waste heat recovery system in Thermopac

  17. CASE STUDY 3 : Waste heat recovery –Boiler Blowdown

  18. CASE STUDY 4 : Waste heat recovery- Jet Dyeing Machine

  19. 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

  20. CASE STUDY 2: Cost Benefit Analysis

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