Task 1.2 Energy-efficiency indices

1. Task 1.2 Energy-efficiency indices Angelo Frascella – Marco Zambelli

2. From DoW • Goal: • Definition of indices for measuring the energy efficiency per process along the supply chain • Activities & Outcomes: • Starting from a literature review, the definitions of the indices will be finalized performing a phase of energy-consumption audits in participating user enterprises and selected external user enterprises from the European Textile industry • Energy-consumption patterns will be identified • Further, the energy consumption models and profiles of the textile sector, by generalizing the results of the analyzed enterprises, will be defined.

3. Preliminary Remarks

4. Preliminary remarks • The reference index is the energy requirements for surface area unit of fabric (kWh/m2) • Considering that fabric production need electricity, heat and water there will be: • kWh (thermal) /m2 of final product • kWh (electric) /m2 of final product • Kg (H2O) /m2 of final product • m3 (compressed air) /m2 of final product

5. Preliminary remarks: the building • Simplification hypothesis: the fabric is produced in a single environment that need air conditioning • So it is possible to evaluate electricity (Ee) heat (He) and water (We) required for air conditioning • Air conditioning needs are influenced not only by season, but also by climatic conditions, day and night differences, light irradiation and external humidity changes • The features of surfaces (horizontal and vertical ones, opaque and transparent ones) affect air conditioning needs

6. Preliminary remarks: the process

7. Preliminary remarks • Each m2 of fabric will need a quantity of heat sum of: • Heat used by each machine • A portion of heat needed for heating the environment

8. Energy needs not related to the process

9. Energy needs not related to the process • Here will be considered energy needs for air conditioning, lighting and possible collective uses (baths, offices, …). • They will be grouped under the voice “environment conditioning” • For this kind of consumption, on first approximation, we can consider there is not direct proportionality with quantity of fabric produced in a year

10. Energy needs not related to the process

11. Energy needs not related to the process

12. Energy needs related to the process

13. Energy needsrelated to the process • Direct proportionality with quantity of fabric produced in a year • Example of path of a product inside the plant: • Raw material in the loom: warping, drawing-in, weaving execution • Control and possible darning of the rough product • Finishing • Wet Finishing (Fulling…) , • Drying • Raising that can be repeated, • Dyeing, • Dry Finisching (Polling …) • Final controls • For each of them there will be energy consumption (including water and compressed air) • Energy consumption for time unit will be function of machine parameters and of product features

14. Energy requirements related to the process • With reference to the previous process: • Loom operations needs electric power and compressed air. • loom speed can be function of yarn thickness (t) and weft complexity (w) • The electric consumption of warping (Ew) will depends also from the power of the electric engine (Mew) • The electric consumption of drawing-in (Ed) similarly will be: • The electric consumption of weaving (Ewe) will depends also from the speed sw

15. Energy requirements related to the process • Darning is a manual operation which requires an electrical machine for fabric flowing: • Wet finishing operations requires steam and heat for the right atmospheric conditions and also electrical power for flowing:

16. Energy requirements related to the process • In the same way consumption of drying, raising, …, can be defined. • A particular operation is the dyeing which requires the immersion of fabric for a certain time in basins with hot colored water. • Energy needs could depends also on time (tu), color (cu), Temperature (Tu), basin capacity (Vu) , Metu as the electrical power and Htu as the heating rated load

17. Energy requirements related to the process: notes • The precise relations and dependencies have to be calculate by a measurement campaign that have to be programmed with Piacenza and DITF personnel • Data collecting have to be homogeneous inside the two enterprises • During these campaign can be examined also transitory (e.g. set-up consumptions) and stand-by consumptions

18. Global needs and indices

19. Total electric consumption • If we refers all to the “hour”, in a hour they will be produced α m2 of fabric. • The global Total Electric Consumption (TEC) will be: Where K is the number of parallel processing and nst the number of repetitions of a step. Est will be: Ew, Ed, ... • This is a FIRST LEVEL index, giving a global data about consumptions • Similar indices can be evaluated for heat, water and compressed air (Total Heat Consumption, Total Water Consumption, Total Compressed Air Consumption)

20. Electric consumption for surface area unit • On the base of the TEC a global electric energy index (EII) can be defined as: • If it is desired the electric consumption (EC) for m2 of fabric for a certain model of fabric it will be:

21. Otherindices • Moreover, for a certain model of fabric there will be specific indices for each step: • These are SECOND LEVEL indices, giving specific data about steps • Similar indices can be evaluated for heat, water and compressed air (Building Thermal Efficiency Index, Wet Finishing Thermal Efficiency…)

22. Indices and data structure scenarios

23. Thanks for your attention