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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

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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In the textile industry, one of Egypt's majorindustries, most of the equipment and machineryappears to be outdated, and measuring equipmentis not sufficiently available.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.



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Schematic Diagram

of Technologies Covered by the Project



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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



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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)



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Current State of Subject Equipment by Factory



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Base Line for Energy Consumption Type ofEquipment by Factory (Zenotex)



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Base Lines of Energy Consumption for 11 FactoriesSurveyed



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Specific Energy Saving by Energy

Conservation Measures



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Specific Energy Savings by Factory



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Base Line for Emission Volume of

Greenhouse Gases for Each Factory

t



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Specific Reduction in Greenhouse Gas

Emission for Each Factory



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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



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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.



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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)



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Documents

11 Dr. Attia