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Energy Conservation Potential of Measurement &Control Systems and Energy-Saving Equipment
In Textile (Dyeing) Processes
by:Dr. Attia Saad El-Din
TIMS - Egypt
Energy Conservation Center, Japan & TIMSMarch 2000
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
7/31/2019 11 Dr. Attia
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Introduction
In the textile industry, one of Egypt's majorindustries, most of the equipment and machineryappears to be outdated, and measuring equipmentis not sufficiently available. Hence, taking
appropriate measures will lead to a substantialsaving in energy.In this context, a quantification of the energyconservation potential of Egypt's textile (dyeing)industry, the effect on greenhouse gas reduction
and the effect of investment for these purposes isexpected to lead to the identification of greatopportunities that would contribute to achievingCDM goals as well as to Egypt's national interest.
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
7/31/2019 11 Dr. Attia
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Schematic Diagram
of Technologies Covered by the Project
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Equipment Covered by the Survey
Dyeing process
Jet dyeing machines, winch dyeing machines,mercerization dyeing machines, etc.
Drying process
Stenters, suction drum dryers, etc.
Utility facilities (heat sources for the dyeing and dryingprocesses)
Steam boilers, thermal oil boilers, and the piping forsuch boilers
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Project Examined Technologies
The following 5 items constitute the technical basis for energyconservation effect.1. Heat insulation of machine proper and steam piping2. Enhancement of measurement and control
2.a Dyeing process: Attainment of optimum dyeing conditions
2.b Drying process: Achievements of optimum dryingconditions2.c Finishing
3. Recovery of cooling water and heat recovery from hot/wastewater
4. Recovery of condensate5. Introduction of energy management system
5.a Optimization of boiler air/fuel ratio and operating pressure5.b Centralized energy management system of utilities
(energy fuel, steam, electricity, water, etc)
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Current State of Subject Equipment by Factory
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Base Line for Energy Consumption Type ofEquipment by Factory (Zenotex)
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Base Lines of Energy Consumption for 11 FactoriesSurveyed
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Specific Energy Saving by Energy
Conservation Measures
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Specific Energy Savings by Factory
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Base Line for Emission Volume of
Greenhouse Gases for Each Factory
t
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Specific Reduction in Greenhouse Gas
Emission for Each Factory
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Summary of CO2 Reduction and Energy Conservation
Potential for 11 factory surveyedEnergy SavingsCO2 Reduction
Calculation resultsItemsCalculation resultsItems
14,449 toe/yearEnergy reductionVolume
44,702 tons/yearCO2 reduction volume
22.4Energy reductionrate
22.4CO2 reduction rate
838.56 million yenInvestment cost838.56 million yenInvestment cost
17.2 toeEnergy reduction/million yen
53.3 tonsCO2
reduction/million yen
5,800 yenInvestment cost perunit of energy (toe)
18,750 yenInvestment amountper ton of CO2
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Effect on Productivity
The promotion of energy conservation through measurement andcontrol recommended in this survey leads to the improvement ofproductivity.
Because optimum energy control in the manufacturing processesallows automatic control of operation at the temperature, humidity,etc., most appropriate for production, the defective product rate
declines significantly (yield improves) as compared with manualcontrol. Moreover, improvement of product quality can be expected.
At present, Egypt's textile products are losing international pricecompetitiveness with Southeast Asian products, and in this context, itis increasingly important to strengthen international competitiveness
through higher quality and reduced prices, thereby promotingexports.
While the improvement of quality, as well as that of productivity, isnecessary, this project is designed to attain these two purposesconcurrently, and it is thus considered to comply with the request ofthe Egyptian side.
Baseline Cairo, March 31 & April 1, 2004
TIMS/EEAA CD4CDM- Second National Workshop (Phase II) UNEP RISO / APEX
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Effect on the Egyptian textile (Dyeing) Industry
Reduction of approximately 22.4% (160,000 toe/y) of thetotal energyconsumption.
Base line for this estimate:
1. Energy consumption by the textile sector: 1,433,000 toe/year
2. Energy consumption by the dyeing industry: 717,000 toe (50% of thetotal energy consumption).
3. Probable approaches to dissemination of the effect of this project
include:1. Financial assistance (Yen loans, "Carbon Fund" including WB
and EPP Fund,2. Technical assistance,3. Development of human resources (training)
Baseline Cairo, March 31 & April 1, 2004
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