Success stories – R&D interventions in textile industry Presented by: G K Medhi Petroleum Conservation Research Association
Vision To Become A Centre Of Excellence For “Conservation Of Hydrocarbons & Environment Protection” For Sustainable Development On Our Inherent Strength
Mission Efficient Energy Utilization And Environmental Protection Leading To Improvement In Quality Of Life
Objectives Formulate strategies for accelerating Conservation. Create mass awareness on conservation potential and methods for conservation. Promote Research, Development and Deployment Efforts. Establish Synergistic Institutional Linkages. Provide training and technical advisory services. Function as a ‘Think Tank’ for the Government of India for proposing policies and plan of action on Petroleum Conservation & Environment Protection.
Education Campaign TV Program Radio Programs TV Spot/Film Radio Jingle PCRA Education Campaign Brochure/Leaflet/ Poster/News Journal Newspaper/Magazine Advt./Article Hoarding/Glow Sign/ Kiosk/Public Utility/P&T Metro Panel/Bus Panel/ Highway Board/CCTV Exhibition/Event/ Internet/Website
Field Activities Industrial Sector / Commercial Bldg Sector Transport Sector Domestic Sector Driver Training Programme Youth Programmes Energy Audit Domestic Workshop Fuel Oil Diagnostic Study Model Depot Study Save LPG Clinics Walk Through Audits-SSI Follow up Studies Other Activities I.T.P. Field Activities International Networking OGCF Awards Agriculture Sector Empanelment of Auditors Demonstration Centre Promote replication of PCRA efforts in Clusters L.I.P. Rectification Common to all Sectors Kisan Melas Seminars/Technical Meets / Workshops
Cluster Based R&D Energy Efficiency in Industrial Clusters - Action Research
Research & Development activities provide strong support to PCRA’s energy conservation efforts by developing and commercializing Energy Efficient products, processes and technologies for energy saving and environment protection. Research & Development
Cluster Based R&D • Focus on energy intensive industrial clusters e.g.. Textile Brassware, Leather, Cold storage, Foundries etc. • Tie-up with engineering institutes along with the industry representatives for identifying felt need / designing of prototypes for energy efficient processes for the industry. • Promote the developed prototype for replication with the help of industry associations. • Promote research in various aspects of conservation in conjunction with IITs, NITs, Council of Scientific and Industrial Research (CSIR) labs etc.
Cluster Based R&D • This aims to improve energy efficiency in entire cluster by developing demonstration units in each industrial cluster. • Beneficiary Industry to contribute in the project cost depending on the size of unit. • About 15 research projects have been approved under the cluster development program in the current year.
Need of the hour • Out of total primary energy consumed in our country, 45% comes from petroleum products. • As a nation, we consume POL products equivalent to Rs. 4,00,000 crore every year out of which the gross import bill is of Rs. 2.90 lac crore. • An effective saving of just 2% in a year by all stakeholders can lead to a national saving of Rs. 8,000 crore. Hence, Energy should be saved at the end use through efficiency.
Textile Industry – identified as a “Energy Intensive Industry”under Energy Conservation Act, 2001. 48% of the total commercial energy production in India is consumed by the industrial sector. Textile industry accounts for 10.4 % of the total industrial consumption. 12 – 15% of the manufacturing cost- includes electrical and thermal energy. The total energy saving potential is estimated to be 15% in textile industry. The Indian Textile Industry -Energy
The Indian Textile industry accounts for 4% of India’s GDP. Textile industry contributes to over 27 % of the country’s total export earnings. Around 8% of the total excise revenue collection is contributed by the textile industry. It generates 21% of the total employment in the economy. The growth potential of textile sector is estimated to be 5.65%. The Indian Textile Industry - present scenario
Requires both Thermal & Electrical energy. 80% of the energy required is in the form of Heat. An estimated 80% - 90% of the electricity used is motive power for driving pumps, motors, drives etc. Energy Requirement …
Humidification plays important role in conditioning of textile yarn & fabric production. It is one of the major consumers of power in textile industry. The developed electronic control system for humidification plants improves its energy efficiency. Energy Efficient Control System for Humidification Plants CLIMO
The supply air fan, exhaust air fan and pump operation will be controlled automatically and their capacities are also optimized to the required level. The damper operation is also being automated in this system. Energy consumption of humidification plants will be reduced by 25% to 60% of the total humidification power in the existing condition. Energy Efficient Control System for Humidification Plants CLIMO
Benefits CLIMO Hardware cost : INR 0.31 Million (USD 6818) Payback period : 17 months Climo
Savings after installation CLIMO 81 Control system has been installed in 7 textile mills.
Energy Saver for energy saving in power loom sector ES • As per studies power consumed by an electrical motor (960 rpm of 1hp) is 6 units/8 hrs work. • At average efficiency of 75% of loom, the idle motor running is 25%. • Wastage of power is 1.5 units/loom/shift. • The Energy Saver Unit developed to suit the drive system of the Cimmco and Ruti-‘B’ type automatic shuttle looms. • The developed Energy Saver Units is an attachment to the loom to control the idle running of the electrical motor.
Energy Saver for energy saving in power loom sector ES The sensor senses the movement of the loom-starting handle and as per the requirement to “start” (ON position) or to “stop” (OFF position); it conveys the massage to the electric motor to actuate accordingly.
Benefits ES Hardware cost : Rs. 3.00 lac per 100 looms Payback period : Less than 6 months
Savings installation ES 200 Energy Savers have been installed.
Energy Cost Reduction Through Convective Air Pre-Drying System CAPD • Drying requirements are frequent in Wet processing. • This forms a major constituent of thermal energy. • Convective Air Pre-drying (CAPD) System has been developed utilizing atmospheric convective air with relatively low energy cost.
Energy Cost Reduction Through Convective Air Pre-Drying System CAPD • This reduces initial moisture retention (MR) of wet fabric at the inlet of the conventional drying system. • The system also reduces the drying load of the main dryer and results in reduction of the thermal energy in the conventional drying system.
Benefits CAPD Hardware cost : INR 0.06 Million (USD 1364) Payback period : 3 months Film
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