In today’s scenario, textile mills across the globe are increasingly consuming more electricity every day, as a result of prolonged use of the equipment in inefficient operating conditions. Textile industry process comes with a large design safety factor, which has to be optimized after process stabilization for optimum power consumption. The energy cost to production cost is around 15 to 20 per cent, and this comes second to the cost of raw material. So, we focus on energy consumption at load end and by optimizing the energy usage of textile machines, we have multiple benefits of less units per kilogram of yarn and improved conditions of machines.
Major areas of potential energy conservation in textile industry
The major power consuming areas in textile mills are:
• Ring frame
• Humidification process
• Electrical distribution network
• Compressed air distribution
This is why the mills now have began their power, air, water, lighting audits, capacitor checks, motor load survey, used oil analysis, condition based performance monitoring.
Areas of Energy Audit
• In the study of energy audit of the running equipment, we can see the visible abnormal symptoms in the inefficient energy transfer in the system using second law of Thermodynamics. Smooth energy transfer from one form to other like electricity to the output shaft speed, belt transmission etc. does not result in abnormal heating, heavy noise, spark etc. whereas,
• Lighting – sparks, in case of contactor switching, loose joints etc
• Heating – in motors, other load equipment coupled to motor Due to Friction, metal-to-metal touch, poor lubrication, misalignment
• Sound – from the equipment in form of vibration, mounting on bed, Noise from belts, bearings, metal-to-metal contact etc.
• During the transfer of energy in the running equipment, if the transfer is perfect & smooth accepting unavoidable losses, then the productive output is higher and the wasted output is reduced. If the transfer is below par i.e. done with more avoidable losses, the productivity falls and waste output increases & dissipated in the form of heat, light, sound which is a sign of visible loss in the equipment operating parameters.
Improving operating parameters of textile industry units towards safety & better efficiency
To reduce the avoidable losses in energy transmission from one state to other in the equipment, we should match our existing efficiency of equipment to suit the process. Simultaneously, we should improve the existing ambient conditions surrounding the equipment to comfort the equipment so that they can provide higher output.