Objective
To heat the cylinders of the textile sizing machines by direct gas burning. The existing technology uses steam condensation as heating medium. Using the gas heating, energy is saved by operating at higher efficiency. It is expected to save 200 TOE/year at project level.
Based on energy costs on the 15th November 1987, the payback time is estimated at :
a) 2 to 3 years for the adaptation of an existing sizing machine to direct gas burning.
b) 1,5 years in case of acquisition of a new sizing machine equipped with a direct gas firing.
A drum dryer heated by the direct combustion of gas, with a power that can be adapted to the dryness of cloth required, has a specific consumption in the order of :
1 kWh/kg of water evaporated
Compared to the consumption of other pre-drying methods (Infra-red gas or electric) for the same production line productivity, the direct heated drum dryer realises energy gains in the order of 20%.
The connection of a drum dryer with a diameter of 800 mm into a line for the continuous treatment of textiles allowed an increase in the productivity of the line of between 20 and 30% depending on the quality of the cloth. From the point of view of evaporation, the drum is equivalent to two compartments of one tensioning frame.
Using a burner with a variable power output in the range of 1 to 50 it is possible to regulate the heat according to the quantity of water to be evaporated. Furthermore, it is possible to limit the heating zone to the drum outputting the material.
This energy saving pilotproject, with a relatively conservative investment, demonstrates the appreciable advantages of drum heating by direct gas burning which can be applied to other applications, especially for the drying of cloth after washing or after pre-treatments such as dyeing.
By analysing observations made during the construction and operation of the first industrial prototype production line, it appeared that some modifications could be made to improve the reliability and performance of certain parts of the equipment. In particular the device used to extricate the material from the drum in the case of a sudden unexpected stop, and the device for the extraction and re-insertion of the gas burners could be improved upon.
Two other drums will be installed on a drying line at the end of October 1992 to dry material after bleaching.
In conventional plants, the distance between the boiler house and the sizing machine is the source of considerable energy losses. Furthermore several studies have shown that sizing machines are practically the only consumers of steam during the summer time, and in these conditions the steam generator works with a relatively low output.
In place of steam circulating through the drying cylinders of the sizing machine, the idea of the project is to fire gas burners directly into cylinders.
The type of burners and their position on the cylinder will be chosen in order to insure an uniform heat distribution through the cylinders. Heat will be readily modulated according to the variations of the thread velocity, by switching on and off the burner; this will also avoid overheating.
In order to improve the thermal efficiency, it is envisaged to utilize the hot and dry air at 150 deg.C leaving the cylinder.
- by blowing this hot air upon the threads
- or by leading this hot air into 2 or 3cylinders located at the end of the dryer.
The consumption of 3.7 kWh per kg evaporated water is forecast to fall to 1.5 kWh/kg. The plant will dry 1200 Tonnes water a year.
Adapting a direct gas burning system to the cylinders of an existing sizing machine, the costs of transformation have been estimated at 400.000 FF and the extra cost of maintenance at 30.000 FF/year (year '86).
For a new sizing machine equipped with gas heated cylinders, the extra cost of investment has been estimated at 200.000 FF and the extra cost of maintenance at 30.000 FF/year (year '86).
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Coordinator
68093 MULHOUSE
France
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.