Objective
Main task was the reduction of the energy consumptions in the textile finishing factory of about 10%, compared to the consumption rates of 1990, showed by the "energetic audit". Such reduction involves electricity, fuels, water and part of those chemicals used for treating the same water.
In order to achieve these results, a global heat recovery system was set up on all the hot gazeous outflows of the processing machines, coupled to the introduction of a continuous detection of all the specific energy consumptions and of the production speeds, to be connected to the kind of treated product and to the machines.
Another task was also the reduction of the polluted atmospheric outflows coming from the drying chambers and from the stenters. We intended to reach values placed under the thresholds fixed by the European regulation. All the waste heat coming from the cogeneration plant and from other recoveries was re-utilized into the process machines, as air or water pre-heating.
This analysis lasted one year and the results confirm an average loss of recovered energy during the summer period of about 10% in comparison to the winter values. As per the electrofiltering cells (for the first time employed with emissions coming from drying chambers of printing machines) it was verified the capability to capture even the urea crystals, caused by the fumes cooling.
The performances of the data collection system correspond to our forecastings, even if the their attainment required more time than foreseen, due to the calibration of the whole system.
The software, specially developed by H.R.S. for this kind of application, gave no problems; of course the system was featured particularly for the customer, as foreseen into the project.
The development and results satisfied the general expectations of the project, for some aspects (environment), they were even better than foreseen.
The success of the data collection and energy management system is connected to the daily use and to the critical analysis of the results. The benefits can be obtained after a medium period of time, since they require fittings and improvements of the production cycles.
It can be of course considered as a benefit the greater involvement of the staff into the management of the production plants.
The positive aspects derived from the use of the plant, subject of the intervention, confirm that, with a detailed study and with a correct application of innovative technologies, the energy consumption connected to the finishing cycles of a textile industry can be GREATLY reduced.
The financial support received from the European Commission was of basic importance in order to decide the proceeding of the realization, so being in a position to reduce the technical/economical risks connected to this intervention.
The first part of the installation represented a global intervention on the whole enterprise, particularly into the finishing department, in order to rationalize the energetic consumptions (electricity, heat, water) in comparison with the actual output, to continuously state its values through suitable instruments and connect them to the production itself, so to evaluate the industrial costs.
The installation treats a total fumes flow of 44000 Nmc/h (instead of the 32000 Nmc/h originally foreseen, because the heat recovery system was extended to three printing machines), at a average temperature of 110 deg.C. All the ouflows of the machines are collected into three units. The heat recovered from the fumes is given off to the water in a closed circuit, so that water itself becomes a thermal vector, for carrying the heat everywhere. Part of the heat warms up the air to be introduced in the same machines, while the remaining part is utilized to heat the industrial water for washing and dyeing processes. The heat coming from the cogeneration plant is employed, too.
Into the saving, even the reduction of the specific water consumptions in the dyeing and bleaching machines is considered; in fact, also the employment of chemicals, joined to the processing and to its cleaning, depends on this water.
The second part of the installation concerns the management system of the energy sources, which collect the data coming from the dyeing/finishing department and from the existing co-generation plant. The collection is carried out by data loggers, connected both each other and to the main unit by means of serial interface for their processing. The program is capable to offer in real time all the data concerning the energy consumptions of the concerned machines and of the output too. In this way, it is possible to choose the various energy sources, so to offer energy to the production plants at the cheapest cost.
The whole intervention involved a reduction of the specific water consumptions, evaluated at about 20% out of the 2000 mc/year, previously utilized.
Differently from the foreseen project, the part involving the installation of an absorption heat pump for the production of chill was cancelled, since the heat was fully directly re-employed. This part was replaced by a wider development of the section concerning the heat recovery and fumes cleaning plant.
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DEM - Demonstration contractsCoordinator
4780 SANTO TIRSO
Portugal