Survival of Textile Sector Through Energy Management and Monitoring
Intimidating resource limitations, increasing energy prices, and consumer requirements for environment friendly products are some of the issues faced by the industry in Pakistan. People have to set for the ambitious target of attaining Energy Efficiency b
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Abstract Intimidating resource limitations, increasing energy prices, and consumer requirements for environment friendly products are some of the issues faced by the industry in Pakistan. People have to set for the ambitious target of attaining Energy Efficiency by reducing energy losses thus reducing the productivity-energy efficiency scarcity of the industry. In Pakistan, the textile industry being an energy intensive segment is open to a higher energy loss rate across various processes resulting in elevated energy cost and losses in productivity which have significant financial impact and making us less competitive. Energy-efficient environmentally sound technologies utilization and implementing cleaner production techniques will help Textile Industry in Pakistan remain competitive worldwide. According to benchmark figures, 10–15% energy-saving potential is envisaged in spinning sector which can be substantiated by the results of energy audits. Keywords Energy conservation • Energy efficiency • Energy monitoring • Environmental pollution • Spinning mills • Textile industry
1 Importance of Energy Monitoring in Spinning Mills The ring frame spinning primary purpose is to convert roving of natural and/or man-made fibers into yarn. For this the roving is drafted to its ultimate single thread size where it is then twisted to bind the fibers together and finally packaged on a bobbin. In total, power requirement of spinning mills and the energy consumption of ring department is the major part of requirement. The imported second-hand
A. Mahmood Synergy Earth Global Pvt. Ltd, 1st Floor, Commercial Plaza, 320 Z-Block, DHA Phase 3, Lahore, Pakistan e-mail: [email protected] M.A. Uqaili and K. Harijan (eds.), Energy, Environment and Sustainable Development, DOI 10.1007/978-3-7091-0109-4_8, # Springer-Verlag/Wien 2012
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Table 1 Common problems resulting in increased energy consumption Points Factors responsible Energy for driving spindles Spindle weight, Lubrication, spindle bearing Spindle tape bending resistance Tape width or Tape stiffness Tape surface air friction The finished Surface Tension of jockey pulley Tension load
machinery or new machines which have more number of spindles with more speed thus have a critical impact on energy consumption. During energy audits trials were carried out for estimation of cost of the power consumption in ring frames. These trials show that the energy consumption depends on weight of traveler, spindle speed, spindle gauge, ring diameter, package diameter, lift, spindle wharves diameter, motor rating, type of spindle tape used, maintenance of ring frames, front roller speed, etc. (Table 1). Escalating energy costs in recent years has propelled energy cost to the top among the cost parameters in manufacturing. The term UKG depicts the energy units used for spinning 1 kg of yarn and is mostly noted as UKG. So it is vital that information on energy consumed per kg (UKG) of yarn produced should be noted and compared on daily basis. The values of UKG show variance fr
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